A tricky one this... the 1.8 Ford diesel has two toothed belts, the belt that drives the injector pump snapped a few months ago. At the same time the tensioner for the cam drive belt broke up (plastic!... I ask you?!) this left the belt slacker than it should have been (it was the plastic "tyre" round the tensioner bearing that actually destroyed itself) but I don't think it was slack enough to have jumped a tooth.
So, the remedy would seem simple... find the timing points, insert pins to lock crankshaft & camshaft, remove tensioner, belt etc, time injector pump, replace pumpo drive belt, replace cam belt... turn engine by hand to check all is well.... then start engine!
If only...
The problem is Fords way of locking the crankshaft, there is a well hidden hole in the block, accessable via a hole in the injector pump mounting bracket, through which the timing pin is inserted, after its plug is removed
This is the difficult bit as it's far from obvious when the crankshaft is in the right place!
We did this all outside in November, but when it was all back together, we thurned the engine by hand only to find it lock up tight... so obviously we got something wrong.... in the meantime another engine came up on ebay locally at £30 it was pretty much scrap value.... this one was from a Mondeo & had a turbo but it's more or less the same engine.
The plan was to swap them over, but having investigated the amount of work involved, current thinking is to investigate, on this engine, how to time the crank & then try again with the other engine...
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