Non-406 1.6 TU series engine problem

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Doggy
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Non-406 1.6 TU series engine problem

Post by Doggy » Thu Feb 15, 2018 1:45 pm

My daughter's 307 has apparently dropped a valve - happened on trying to start, engine turns freely in either direction for about half a turn, but won't go all the way round. Timing belt seems intact.

Managed to recover it last weekend, but haven't attacked it yet. (Another family member has loaned them an old Rover 200 for now). The car is a 57-plate 1.6 petrol hatchback, Serviceballcocks insists it must be a 1.6 i 16v 110 (TU5JP4)

Thinking I'll strip it down without much expectation of recovering the situation, (but might as well have a butchers). Suspect the best hope of sorting it at moderate cost would be a known good s/h engine - we can afford a few months to resolve it, but not too much of the folding stuff.

All suggestions that don't involve a viking funeral welcome....
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Re: Non-406 1.6 TU series engine problem

Post by steve_earwig » Thu Feb 15, 2018 3:30 pm

Get an endoscope/boreascope? Dropped valve, bent valve, valve seat fallen out.... I don't suppose it's going to be good, whatever it is, so you're best bet is to do the bare minimum to diagnose it to make sure you called it and then bin it.
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Re: Non-406 1.6 TU series engine problem

Post by Welly » Fri Feb 16, 2018 9:15 am

Good call, endoscope down the spark plug hole (remove all plugs for easy of turning) them get a willing* helper* to turn engine by hand...hopefully you'll see enough to confirm.

What's the mileage and how does a modern engine drop a valve anyway :?
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Re: Non-406 1.6 TU series engine problem

Post by jasper5 » Sat Feb 17, 2018 12:47 am

You should be able to tell if you have a dropped valve by removing the timing belt, cam covers (rocker covers) and spark plugs.
Place a long screwdriver in each plug hole and check if the pistons are near the top or half way down....it you can get the pistons where all of them are about half way down (in a position where the valves cannot touch a piston) then turn each cam and see what happens to the valves...see if any of the cam buckets are further down than the others with the cam lobe in the closed position...this will tell if you have a bent/dropped valve.
You can remove each camshaft block and do the same check...see if any valve is not sat back level with the others.

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Re: Non-406 1.6 TU series engine problem

Post by Doggy » Sat Feb 17, 2018 10:11 am

Thank you for the suggestions people. 8)
I reckon I'll go with jasper5's approach as it has a good chance or revealing the cause, (and I don't seem to have too much success with endoscopes). Hopefully have a look over the weekend.
A quick scan of fleabay revealed a couple of potential replacement engines in the region of £125/150, but I'd have to factor in a clutch kit & possible hire of a hoist, so worth spending a bit on fixing this one. (I think it's sub 100k miles and always sounded really sweet / pulled well).
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Re: Non-406 1.6 TU series engine problem

Post by jasper5 » Mon Mar 26, 2018 8:57 pm

Did you ever get round to sorting this out Eric?

I just got round to looking at the Twingo today...took the cam cover off and found a broken valve spring and no exhaust valve in number 4 cylinder.
Took the head off and found the valve seriously bashed up on top of the piston and a nice crack across the piston.
Head is ok but it needs 2 new valves and a piston....bore is fine as well, surprisingly!
Piston will be removed tomorrow and parts ordered.

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Re: Non-406 1.6 TU series engine problem

Post by Doggy » Mon Mar 26, 2018 9:24 pm

No John, I haven't got round to it yet. :oops:
Not massively urgent since prospective SIL has been given an old Rover 200 on indefinite loan, but I must make a start soon.
Having to work most of Easter, (maybe for the last time), maybe the weekend after........
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Re: Non-406 1.6 TU series engine problem

Post by jasper5 » Tue Mar 27, 2018 12:33 pm

Not much fun working Easter :( I'm trying to retire but folks keep bringing me problems!

Got the piston out this morning, it's completely smashed in half around the gudgeon pins...amazed the bore isn't scratched!!
Off to the engineers tomorrow to get a costing to see if it is worth fixing.
I'll let you know the cost then you might have a rough idea with the 307.

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Re: Non-406 1.6 TU series engine problem

Post by Doggy » Tue Mar 27, 2018 12:38 pm

Best of luck with it.
As regards retirement, I'm planning to only work 3 days a week from the end of April and jack it in completely about this time next year.
We'll see........
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