T4 2.4D - Catastrophic timing belt failure - Now what?

[fingersinterlacd]

I folk,

Through a series of failures and fixes, which starts with a problem with the amp in my T4, goes via a failed laptop power supply, being hit by a cop car while cycling to work - nearly tore my bike in two, my welder blowing up, left hand side door handle failure, gear selector and linkage replacement, serpentine belt destroyed, harmonic balancer replaced, and ends with pistons and valves and bad bad noises... Good month hey. What next?

The engine in my T4 had the timing belt etc done less than 20,000k ago, has done 159,000k - pretty good for a '96 vehicle, and otherwise ran really really well. Turns out the large bolt holding the harmonic balancer span lose and the gear that runs the timing belt slipt and yuk. My fault, yep. Did I mention I spent a night in hospital after being hit by a cop car while cycling to work? I'm not angry or upset about the engine, I'm more happy to still be walking.

So... Now what should I do? Are the pistons likely to be damaged? Can I just rebuild the head, or replace it? Am I going to have to rebuild the engine? Should I replace the engine? I don't want to write the vehicle off ... I love it.

A

[Sunny43.5]

Forget every thing else just go out and buy alotto ticket and if you win you bloody deserve it !! as for damage Jmac can tell you that most of the T4 engines have apolicy of meetings between the valves and the pistons if timing belt goes out for lunch .

[Jmac]

Sorry to hear about your bad luck mate, really I feel for ya. You said the belt was only just done, did you do it? when kit comes from VW it comes with a new bolt, there is 2 different lengths and both have different torque settings, anyway enough of that yours came out, without doubt the valves will be bent, guides damaged, possible piston crown damage too. It may be a throw away. Id be looking for an engine to be fair, same or replace with a 2.5. Check Howards thread he changed the one in his sons and I helped him over the ether and phone to get the immob sync,d. not a bad job just time consuming and you have to go through all the timing belt procedure again for peace of mind.
Hope luck turns for the better
Jmac

[Rebuild]

Do the conrods bend as well?

[Sunny43.5]

Yes I still have a complete 2.5 petrol engine with gearbox under a tarp in the driveway , I do not know what condition its in as I bought it with a view to fitting to my sons but I could not find the electrics needed ECU instrument binnacle etc. The people who I bought the engine from said it was originaly driven to them and then dismantled for parts . Oh and yes his van was a 2.4 D as well the injector pump had developed a leak and I could not justify the $1500 rebuild for the sake of a $10 seal so we eventually bought a running T4 2.5 from Ebay stripped it and fitted all parts to his van . Its still running strong 2 years on after the swap and yes Jim was a big help at the time with a couple of things . Thanks Jimmy

[jets]

Now what should I do? Are the pistons likely to be damaged? Can I just rebuild the head, or replace it? Am I going to have to rebuild the engine? Should I replace the engine?

There are lots of posts over on the T4 Forum in the UK for cambelt breakages. From what I have read, valves bend[not all 10] the camshaft breaks & hyd. lifters get damaged. Generally the pistons are undamaged apart from some marks & are not removed & the heads are rebuilt.
Prices are cheaper as we all know in the UK but can be bought aftermarket here in Aust. It depends if you could buy a good s/hand engine & at what price. Imparts I believe can supply all the parts. I know they can for the 2.5TDI.

[fingersinterlacd]

Forget every thing else just go out and buy alotto ticket and if you win you bloody deserve it !! <snip>

Best advice. It's my daughters birthday tomorrow, I'll buy lotto tickets tomorrow.

<snip> You said the belt was only just done, did you do it?

Nah, a pro did that about 10 - 15,000k ago. Had no issues with the pro work I've had done on it, both mechanics who have worked on it have good reputations, and lived up to it, and I've found them to be reasonably priced.

My issue was, I was trying to save a few bucks and did the the harmonic balancer myself. I knew I hadn't torqued the bolt up properly, and knew it needed replacing with new. My mistake. But oh well, ya know. I'm the kind of person who laughs at my mistakes rather than kicks myself. I know mechanics well enough to get myself in to trouble, but I entertain myself in the process. I've done heaps of stuff myself over the years, on a few different vehicles, this is the first time it's gone on to cost me more.

<snip> Hope luck turns for the better Jmac

Having (mostly) walked away from an 80k/hr bike vs. car impact - cop was speeding through town on his way to a job - I'm considering myself possibly the luckiest person I know right now


The only thing that's constantly disappointed me about my T4 2.4D is the, well... the naturally aspirated dieselness of it all. I've even been tempted to sell it a few times.


Now my engine is broken. I see opportunity.


My T4 is my dream camper: LWB; Syncro; camper fitted out by TRAKKA. 4x 100 watt amp, JVC 6x9's up back, fair quality 5's in the doors; big ali roo bar; tinted windows, sliding window on drivers side; 360 rotating front seats; sink / stove / fridge under the double bed; 60L stainless steel water tank underneath plumbed up to the sink with electric pump; tow bar; 90 watt solar panel up top with PL20 charge regular with 1000 amp shunt, (isolated) gel acid deep cycle aux battery, another 120 watt panel waiting for install; 225 light truck tyres. I've lived out of it for weeks on the road. Most of the mods were TRAKKA's camper fit-out, like that when I bought it secondhand back in 2008.

I use it primarily for camping, and moving stuff, including towing heavy trailers full of furniture or camping gear. It's great off road, and the Syncro has shown me what difference AWD makes in the wet and on unsealed roads. I seriously love this van.

I've got a Peugeot 306 HDi as my day car, awesome fuel economy and wonderful suspension that one, so fuel economy in the van isn't much of a consideration. I'd rather be able to tow a big trailer up the hill and not be stuck in third gear doing 40-50k/hr, as has been the case with the 2.4D.

I realise the more power I put through the drive train the sooner I'm likely to wear or break something in the Syncro. Such is life. Another project when the time comes. It's a vehicle of passion.



So, assuming cost and time aren't an issue - I know this is going to require a fair bit of both of those...

Can I get some opinions on what would be my best flavour of engine to use given the circumstance outlined above.

[Golf Loon]

I have a 2.5tdi engine from a t4 sitting around here. 150ks. I drove it, pulls like a train.
Comes with engine loom and ecu.
Bolt in and make yours the ultimate van.
$2200 be quick, there are a few that want it.

[Sunny43.5]

I would agrre with Golfloon its the same conversion I did to my sons T4 two years ago the van goes like the clappers now , Just remember we also changed the exhaust and fuel tank and lines . Howard