Thanks for all the interesting replies.

More information

When i had the timing belt water pump replaced several years ago, that garage didn't replace the timing belt cover, because but was broken.


So the car had no timing belt cover.

A different guy replaced the belt etc a few months ago.

This third garage where it was recovered to had a look last week as they thought I'd just had an alternator failure, when discussing over phone. When it was inspected they saw the timing belt broken too, and the auxiliary belt twisted around it.


Yes, perhaps the second guy didn't tighten up a bolt or something, and the first garage didn't out in a new timing belt cover, but I am not going to chase these up, as none were malicious.


I'm now having to decide between engine replacement or head off and valve piston replacement - just a cost comparison.

I think I'll go for replacement, as it's still cheaper than a replacement car, especially given secondhand prices right now, plus I love this car - I have a brand new Suzuki Vitara 4wd on hire, and I hate it. It's far noiser, poorly designed, compared to the 12 year old Freelander, which is weird.

Thanks again.

Hi,

can not help with your decision

but its good to hear the extra details behind what has happened, it explains the situation, thanks for updating us

 .
my first ever FL2 and I did keep it longer than most other cars!
But its now gone way up Norf

When I did my cambelt change I found that a bolt was missing from the upper cover and a lug was broken and was just hanging on. I glued it back on but it wasn't strong so I reinforced with an aluminium plate - not pretty, but effective.
AFAIK the cam belt cover had never been off before and I've had the car from 6 months old and 5K miles - was ex-demo.

 Jules

I have finally had the broken FL2 transported home where we are going to remove the head (first) and have a look ... I shall of course update here with the results.

We are just curious what happened and the effect on the engine, and maybe it can be economically repaired by DIY.

thanks for all your input

thanks . we await your pics Jules

Car was shipped to my brother, and arrived same time as me in my "new" Merc estate.

Rolled it off the lorry and after a few weeks the engine has now been rebuilt.

There were signs of cracking on valve train. I'll add photos if anyone wants as I can't really identify them - not a mechanic.

Mind you, neither is my brother
He has a few actual mechanic friends, and are stumped by this : see attached video

https://photos.app.goo.gl/S5CjL9e4XmHQTNuo9
I

Let me know if that link works etc?

It's just a video of the engine turning over as video format as that's the de facto audio format nowadays.
Update - added some more photos of the engine as it was disassembled.

I thought it was air lock in diesel.

The mechanics are concerned that it doesn't sound like compression ...

Answers please, diagnosticians!

According to photos, another engine ruined by a valve dropping into cylinder due to the rocker and valve stem wear...

Also see https://www.freel2.com/forum/topic32690.html

No. Wow.

Timing belt broken by alternator belt coming loose and twisting around it.

Probably inevitable though, in the photos they're well worn..

Probably the another way around...
Valve dropping, engine suddenly (or partly, for a moment) seizing, timing belt jumping out and "mixing" with the accessories belt.
But, like one veteran on here once said, I may be far removed from the truth...

Apparently the alternator pulley came off, instigating the accessories belt then timing belt removal.

Wondering if anyone can tell us why it won't fire - churning over in the video.

didn't sound like it was compressing

suspected timing shift - although all TDC references were aligned ok, it turned out that the TDC mark on one of the camshafts had been forced awry - two new camshafts and it fired up fine.

Last edited by pmabz on 25th Apr 2022 5:24 pm. Edited 1 time in total

Not unheard of when aux belt goes the flailing ends can end up inside cambelt cover with natural consequences.
I sure I have read of somebody who modified the cambelt cover so no chance of aux belt getting in there.

re the belt coming off - the timing cover wasn't present - it had rusted and when local garage changed the timing belt a few years ago, they didn't replace it - said it wasn't really needed!

Seems like the alternator pulley came loose, throwing the aux belt off, to catch in timing belt

Anyway, the car is now going

damage caused was cracked rocker arms, crankshaft sensor wires ripped off, one camshaft had been torqued out of reference ( the TDC mark on one camshaft had shifted) so bought two replacement camshafts £100 and it fired up.
complete new head parts, head was skimmed too
Also new recon turbo £400 , new injectors £900 while we were in there

Not sure what the budget is yet but it is nice to get it on the road as my replacement car is fast but low, and seems to have given me sciatica!

It sounds like your issues were caused by the first garage not putting the belt cover back on place. They're talking BS about the cover rusting and not being needed.
It's absolutely impossible for it to rust, as it's plastic. And it's absolutely vital, as the cover is there to protect the belt and pulleys from debris, and water thrown from the front wheel.
I really hope you had the missing cover replaced, or the whole scenario could repeat itself later on. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

Thank you - I agree too.

total cost of repair was £3300 excluding labour (brother did it for beer)

Going better than it ever was, too.