Cam belt change blunder, help !

[johntom]

Hi
I have attempted to change the cam belt on my 2005(55 reg) 307cc 2.0 petrol (having successfully changed several belts on other cars before). However now the car turns over but won't start (no nasty noises) P. planet says p0341 which is camshaft sensor making me think the timing is out so i have stripped it back down to re check.
I didn't have the correct timing pins so as a last resort I used a breaker bar under the chassis leg to crack the Crank nut - the car started fine then.
I used I thin rod through the plug holes to get the pistons roughly level, which coincided with the exhaust cam sprocket 'key hole' lining up with the 5mm hole behind it, so I used a drill bit and thought all was well.
I couldn't see a timing hole on the inlet cam sprocket which looked like a solid pulley?, also the crank sprocket is on a key way, not floating.
Having fitted and tensioned the belt, I marked the sprocket positions (I should have done this before, I know !), then turned the crank several times and the marks lined up, but what went wrong ?
Also I need to start from scratch and reset the 3 pulleys, if I start with the Pistons exactly level, then pin exhaust one again (which I'm sure is right), I should be able to remove the belt and pin the crank shaft (when the correct crank pin arrives), but what about the inlet pulley

[xantia_v6]

Maybe the camshaft timing sensor has been disconnected or damaged?

[Oldpug]

If you're sure you have timed it up correctly, flywheel locked with pin and both camshaft gears locked with pins (the only way)


If so you must have an electrical problem? or what I call an "elbow problem"? when taking it all apart you could have damaged a sensor,dislodged a plug,or in moving wires about you may have identified a dodgy wire and now its broken. Did you disconnect the battery when doing the job?

[johntom]

Hi I suspect either (or both) the crank and inlet sprocket may have moved. I am waiting arrival of the timing pin set, however i dont think it has the correct the pins for the cams on this RFJ engine ?My plan is to set the Pistons level (2&3 are slightly high at the moment) then pin the exhaust cam with a 5mm drill, then remove the belt, tweak the crank into position and pin with the correct tool, then work on the inlet cam (may have to remove the cam cover) ?
I originally thought I might have broken the wire to the crank sensor when I pulled it from the clips however I tested ok for continuity.

[Oldpug]

As long as the cam sprockets and crank are locked in the correct place its timed,checking pistons is unnecessary and may confuse the issue.As long as they are the correct diameter anything can be used as pins,bolts,drills etc.
By the way early EW engines with the crank pulley secured with FOUR small bolts,the pin location is at the timing end through the flange.
Later engines with the crank pulley secured with ONE large bolt the pin locates a hole in the flywheel at the back of the block.

[RichardW]

There should be a hole in both cams. Inlet (front) is at about 5 o'clock, and exahust (rear) is at about 7 o'clock. Crank setting position is via the flywheel with the big dia pin we talked about in a previous thread. Tensioning procedure says to fit the belt, then remove the exhaust cam pin then tension before removing the crank and inlet pin. Rotate 10 times, and the re pin the inlet cam and check the tension (pointer should align with the notch on the back plate). Almost certain I would think if you have tensioned with only the cam pinned you have pulled the crank round out of synch. At least it appeared to turn over by hand, so there's probably no mech damage.

[Oldpug]

Surely though if it was just a "tooth or so" out the engine would pop and bang and try to start.? any more than that out and it would have locked up and bent valves.

[johntom]

Hi
I turned by hand several times, then tried to start it. No nasty noises were heard it just didn't fire up?

[RichardW]

Not necessarily - on the HDi at least, it checks for cam and crank synchronisation, and unless it's there it won't start injection. Don't know how far out it has to be though before it fails the check. In fact the cam sensor is not used for anything else on the HDi and can be unplugged once the engine is running! I agree that it does sound rather like an electrical fault, but it's got to be worth a re-check of the timing as it was done without pins. A google on the fault code suggests it can be set by prolonged cranking, so it may be a red herring.

[johntom]

Hi
I think I need to start from the beginning as I don't think the timing is right. The pins have arrived so I will reset it tonight and report back.

[johntom]

Hi
Just an update, I started from the beginning, using the correct crank pin and a drill in each of the cam shafts and it started first time ! Moral of the story, don't cut corners !

[RichardW]

Nice one, bet that's a relief!