What in the bloody blue blazes happened??

[Billysgoat]

I would appreciate ya'lls input on this, I have some ideas on what happened but do not know enough on these motors to make more than a guess. It's gonna be a long post, so grab a cup of your favorite beverage and read on, I know how it is trying to fix stuff online, the more info the better.

Background on the motor in my truck;

Needed all the accessories for a 1.6 engine, had a good motor and IP, but did not have many of the brackets etc. Found a car at the local junkyard with a complete motor and was able to buy the whole car for $200. Got it home and found it to be an aftermarket turbocharger kit equipped car. No, I didn't look that close at it in the yard, saw a complete motor and started haggling    Got the car home and looked over the engine, no water in the oil, turned freely, hooked up a fuel pump and got it to sputter. Pulled injectors and had them cleaned, pop tested etc. Reinstalled the injectors, hooked up fuel lines to a can and got the motor to run. Changed oil and filter, ran it about a minute and changed oil again, this time adding some motor flush. Ran motor for about 30-45 seconds, oil and filter changed out again. At this point I was happy with everything and pulled it from the body.

Before installing in the truck replaced the timing belt and anything else rubber on the motor that I could get replacements for. Got the motor in the truck, had exhaust put on and started out just easing around town in it just in case. Ran great and nothing came up so I started driving it back and forth to work, 35 miles one way running about 65-70 MPH. Other than the turbo to manifold bolts backing out no problems with the motor whatsoever. Went like this for about two weeks until this past Thursday.


I finally had enough of the lack of oomph and unlocked the fuel screw, made a few very small adjustments to it (just enough to raise the idle a touch) locked it back down with the lock nut and carried on to work that night. The next day I drove over early to eat with a friend and the truck stayed parked for about 3 hours. Got in, fired it up and left the parking lot.

When I let off the go pedal and clutched it to shift into 2cnd gear the motor started with a horrendous banging noise (not sure on the timing of events here, but I think thats about right). By the time I could get far enough down the road to get off the road the banging had ceased to a loud tick and the motor was missing badly. Shut it off and coasted into a C store parking lot, got out and popped the hood. No holes in the side of the block, no oil pouring anywhere, nothing was amiss insofar as I could tell looking at the motor externals. Restart the truck, cranks and runs with a bad miss and a loud tick, but otherwise smooth and quiet.

Trailer it back home the next day and start tearing into it, this is what all I have done and found.

Timing was checked first, found the pump to be about 1/2 turn of the sprocket out of time and I cannot for the life of me remember now in which direction it was out, I want to say the timing mark was towards the front of the vehicle. Belt was still tensioned good but showed signs of fraying from rubbing against something. The cam was about a 32cnd of a turn out judging from it's relation to the top of the head, did not have the timing tool with me so that could have been from the flywheel not quite aligned correctly.

Pulled the head to check for valve piston contact, all valves run out true to the naked eye and seat correctly. No sign of contact with anything on any valve. The pistons looked good, again no sign of contact, no cylinder wall scoring and all pistons come up to the same height above the block and move freely.

Have not pulled the oil pan and at this point really see no need without more evidence of gross mechanical failure. Studs, a metal HG and a new timing belt will be ordered tomorrow (Monday) and I'm going to take the pump to be checked out by a local injection shop.

Anything I might have overlooked, please point out, anything else you need to know, just ask. I want to figure out what the heck happened here and what, if anything, I can do to keep it from happening again.

Sorry for the book, but the more info the better  

Thanks,

Billy

[coke]

The belt fraying concerns me, as two things can cause this: Bearing failure in the IP, and alignment of the IP + bracket.

One good thing to always look for after you give the engine two complete turns after tensioning the timing belt is how its riding on the pulleys.  Then, if all looks well start it up and then shut it down after a second or two of running and look at how the belt is running.

It sounds like the belt skipped a tooth or two and that may be related to the fraying somehow.

[jtanguay]

lack of oil pressure? failed bearing? possibly bad injector (even though they were re-done)

to check for a bad injector, crack each line with a rag to soak up the diesel.  if the knock goes away then voila.  (maybe some dirt clogged up the nozzle and its spray pattern is all screwy)

did you change the fuel filter?

[Billysgoat]

lack of oil pressure? failed bearing? possibly bad injector (even though they were re-done)

to check for a bad injector, crack each line with a rag to soak up the diesel. if the knock goes away then voila. (maybe some dirt clogged up the nozzle and its spray pattern is all screwy)

did you change the fuel filter?

Oil pressure was good to the best of my knowledge, I don't remember seeing it in the red. Bottom end of the motor turns over great, no binding or slack throughout the rotation. Once the knock subsided to a loud ticking the motor was running fairly smooth even with a miss.

Brand new filter with under 200 miles on it.

I was not going to, but will pull the injectors and have them checked out as well.

My main concern is the pump jumping timing, what can cause it?