Major Timing Chain Headache please help!!

Major_T

Hi, long time lurker here, I just changed the chains on my '06 zafira 22YH using the pdf guide and the "how 2" on this forum which was extremely useful, especially vocky!

My problem is that after rotating the engine to check all ok it will not get to TDC! 🙁 It will rotate to about plus 5deg or minus about 15deg, and it won't go in the zone in between.

the coloured links all line up with the sprocket markings, and the cam sprockets are properly located in the cams.

What could be wrong?

I must have changed the chain at about +5deg (unintentionally) but that wouldn't cause a problem, would it?

Cheers...

evocarlos

did mine last weekend
i put the engine in tdc on the lower pulley to the casing mark
then lifted the rocker cover to make sure the cams were in the right place
then i just removed the hole chain kits and refitted making sure all the marks meet the right places
and making sure to activate the tensions
i did have to rotate the exhaust cam anticlockwise a few degrees to fit the sprocket
then gave it 2 full turns to check the alignment the marks wont line up after rotating it 2 turns

even if the timing was set at 5 degrees as long as all the sprockets are fitted in there key ways and the chain links meet the marks you can't go wrong

your timing looks just as mine did

evocarlos

just to add if you want to get bang on tdc you will need to remove the spark plug in no 1 cylinder or it will only go before or over due to the compression in the cylinder 🙂

Major_T

cheers, trouble is i've already fitted the chain and have this problem, I started the job following the pdf which didn't mention the casing mark so i put it to TDC by eye and was probably a little bit out from the start (or it might have moved a bit)
However, I can;t see why that would cause my engine to lock up and not rotate? Because the sprockets, marks and links are all idiot-proof?
feeling stressed! 🙁 what should I try next? remove the chain and refit?

evocarlos

only way for it to lock up is if the valves touch the pistons and that would be if the cams were 180 degrees out but looking at you pic there in the right place
have a watch of this its in german but is explained well in the video it may help discover the issue

https://www.youtube.com/watch?v=GpigBDiBVlE

Major_T

Just thinking, when I took the old chain off, the coloured links didn't line up, should I have lined them up before removing? Im really stumped

Daz

The link wudnt have lined up on the old chain on removal...

I'd check to make sure the key is still in the crank and that it didnt drop out when u pushed the gear on

Major_T

Thanks daz but the key is still there, I can see it when I pull off the pulley.
I guess this is a pretty unusual problem? Hope it's something silly...

Major_T

Tonight I had the chains off, checking everything, everything rotates freely except the crank.
Sitting down going through everything again, I just realised I never refitted the 10mm bolt behind the blanking plug!!!
What does that do? Would that cause this problem?

jwalker

That's for the chain guide, it shouldn't stop the engine from rotating

Major_T

D'oh, yeah I just went out to check.

The crank stops both ways when pistons 1&4 are 0.7mm from tdc. Not touching valves, they have room to move down still. Looking like an engine rebuild or swap at the mo which is crazy, it was running before I started 🙁

IDI_AMIN

The only reason i can think of why your crankshaft is not rotating fully is the valves must be touching the pistons unless there is something wrong with your crankshaft or inside in that area you should start again take chains off .Does crank rotate with chains off?
I see you have Zafira z22yh engine is that a mistake . i dont know what the difference if any when doing timing chains but if you are using a guide for Z22se engine chains maybe this is where you are going wrong

evocarlos

IDI AMIN said:
The only reason i can think of why your crankshaft is not rotating fully is the valves must be touching the pistons unless there is something wrong with your crankshaft or inside in that area you should start again take chains off .Does crank rotate with chains off?
I see you have Zafira z22yh engine is that a mistake . i dont know what the difference if any when doing timing chains but if you are using a guide for Z22se engine chains maybe this is where you are going wrong

my chain kit is for a z22yh fitted to a z22se 🙂

Matt

One of the camshaft sprockets is different between the se and yh kits

IDI_AMIN

Matt said:
One of the camshaft sprockets is different between the se and yh kits

Will this not cause problems then if you buy a kit for se and fit to a yh .the head gaskets look the same .so are they timed up the same way?

Matt

IDI AMIN said:
Will this not cause problems then if you buy a kit for se and fit to a yh .the head gaskets look the same .so are they timed up the same way?

Yeah, as Carl found out :-)

You need to have the correct sprockets fitted

IDI_AMIN

Matt said:
Yeah, as Carl found out 🙂

You need to have the correct sprockets fitted

Silly billy carlos .You see that guy in another thread with the broken notches on his cam sprockets it would be interesting to know which brand of chain kit he used

evocarlos

i think the yh sprocket will fit i just wanted it to be right so vocky helped me out and sent me a new z22se GM sprocket
the yh sprocket only has one notch for location whereas the se has 2

Major_T

Cheers guys, yeah the chains are off and I'm trying anything to get the crank to rotate 360deg but it just won't. Tried moving cams etc, the valves aren't touching. All I did was change the chain! Aaarrgh!!!!

vocky

from your pictures the chains are correct, but if the engine will not turn over then perhaps something has fallen into a cylinder ?