help bad 2.0hdi engine miss/ rattle rpm 2200/video added

[adaptorman]

all all new member her hopeing for a bit of help with my old 406 2.0 hdi 110bhp , never realy had too mutch off in the way of problems with it , until i had the engine had overheated ,
the car was recovered and as it was overheating the clyinder head was removed , skimmed,pressure tested and new gasket set fitted ,along with new timing belt
now the bad news they phoned me to tel me the car was still over heating and may have a possible cracked block , and the engine wont rev past 2200rpm
i thought nightmare , then got my code reader out to see if there were any possible ecu faults , they were 25 faults , but i assume the garge had been unpluging sensors etc which may have stored on the ecu, anyway i cleared every code and started the engine , and then re checked for any codes , only fault code i have is a heater relay fault , but i carnt see this causeing the main issiuse that ill explain ,
im not machanic , but i thought id check and bleed the water and found top rad hose hot and bottom cold , removed thermostat , jet washed heater matix and front radiator and still same happernd , it over heated ,,next i removed the cambelt and removed water pump to find the inpeller had come lose , i thought why the hell didnt the garage do this , anyway 1hour later replaced pump re timed the engine and bingo no over heating,heaters hot everything sound

now the bad issiuse the engine will start first crank off the key and idiol fine on 4 clyinders as i rise the rpm to 2000rpm everything seems fine , but soon as i rev to 2200rpm the maxium the engine will rev , i hear a suddern rattle(like a injector rattle ) and and engine will drop on to 3clyinders (like if u unplug a injector ) then come back onto 4clyinders and idiol fine again
ive removed the injectors this morning , and checked the compression which all seem very good for a 168,000 engine but i carnt check these above 2200rpm with engine cranking , i think this maybe a knackerd injector as when it missis and drops onto 3clyinder i get a strong smell of eye stinging fumes ,

due to having no ecu fault codes i wont assume its the accelerator electronic unit/common rail pressure sender/or main pump as my scanner shows everything is fine , ive also done a video below of the scanner and what the engine dose ,
http://tinypic.com/r/112g80k/7

[adaptorman]

found the issiuse , i couldnt belive it , a garage reskimmed and they refitted this

notice 3 shiny valves , after removeing them i found these had been hitting the pistons , ,i reckon idiol didnt re time it correctly , which was the rattle i could hear,
next look at this valve

very poor why they didnt sort this ive no idea
so i threw it in the scrap bin and bought another and refitted it

more like a head , refitted and re timed correctly , revs and sounds sweet as a nut ,
right ive a small question what fits on this turbo , as ive only 2 soloionods on the bulk head,ones goes to egr valve the other runs onto wastegate , yet ive this spare


i can find any pipe for it or were it should be ?

[steve_earwig]

What a bunch of monkeys! Glad you sussed it out! What's the deal with the valve? It looks like it's either too small or they're seriously ground it to try and eliminate seat damage

I'm not actually sure what you're asking about there Some versions have 3 solenoids, one extra for something called an air doser which dumps air into the inlet to reduce emissions.Or something

[adaptorman]

cheers tbh , engine started fine only when reving i had missis, rattles,engine cutting out , i personaly blame the garage who didnt take time to do the job properly (luckly id bought it this way ) now sorted sounds nice and drives pretty well
regards the 2 solionds ones contected to the egr the other the the turbo wastegate , but if you look on the other pic on the turbo you,ll will notice a spare hole were a pipe should fit , as i carnt see one ill just block it off, as theres no other pipes on the car for it , mind its a early w reg 110hdi

[steve_earwig]

Errrr... Do you mean that thing sticking out behind the turbine? Isn't that for the bolt locating the air duct?

[adaptorman]

Errrr... Do you mean that thing sticking out behind the turbine? Isn't that for the bolt locating the air duct?

no this

regards valves they must had got the timing wrong causeing 3 to hit the pistons, and the other may have been a bad valve seat as the engine had over heated , either way very bogy idiots , just shows you , i went to the garage and asked for the guy who did the work , ,i said ur the guy who fixed a head on a 406 etc, he said yes i removed the head skimmed it and refitted it and it wouldnt rev,, i said why didnt you get the timing correct and see this bad valve???? he said ,i was only told to remove refit , i said fair enoegh ,but to time up wrong and cause valve damage isnt on then charge 520. labour , is a rip off , i asked them for a refound they stated, sorry its beem tampord with we wont accept any responceabilty,, i thought wtf i said u caused the issiuse , i said i bet u wouldnt do this to ur own car ,u pr...k , i said but seen as u or a wa..k company wont do anything about , ill do this threw the head clean threw counter window and walked out , not the best way , but i was mad

[DiscoPol]

[Busman]

Oh dear. Possibly throwing the head through the window was totaly understandable but not the best option.
This is yet another example of why I started to get my self some tools and start to look after my own cars 25 years ago. My theroy was and is I can make the same mistakes these monkeys make and still save lots of money. Seems to have worked well so far.
Try to stay cool!
Richard

[steve_earwig]

Good heavens I hope there's no repercussions. Yes, very satisfactory, the alternative is take the buggers to court, trading standards, blah blah blah and it'll end up in front of some old winker who doesn't even know what a cylinder head is

Thanks for the arrow, I didn't even see that bit before. I've still no idea what it is though, nothing else seems to be down there. Mind you, the diagrams aren't the best in thing the world and mostly show the other side of the turbine anyway

[adaptorman]

i think the guys were more shocked seeing a flying head , i agree not the best option , its not recomended , iwas so pissed off with them for a shocking bodgy job ,came out worse then when it went in ,
sure if a car is takern in for overheating runing rough , sure anyone in there right minds checked the waterpump and valves specaily when its been over heated ,,,, cars runing really well no smoke great starter,turbo sounds nice