Vauxhall Zafira 2.0 tdi - 2001 Vauxhall 2.0 tdi not starting

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Mon 2 Jan 2012 15:54
Vauxhall Zafira 2.0 tdi - 2001 Vauxhall 2.0 tdi not starting - crunchr53
So the story goes... We had a turbo failure on Our 2001 Zafira 2.0 tdi. The engine proceeded to suck oil in through the turbo then back into the intake, using it as fuel. After one of the scariest moments of my life with the the engine just reving out of control and not turning off, i finally stalled it, probably just before full self destruct.

After this we began the repair process. Grabbed a new turbo and and fitted it, started it, and it started to go off again free revving. But this time it turned of with the key. So now we started to dig deeper and took out the cam. Under the cam we found that about half of the intake/exhaust rockers had been just smashed to bits. So we proceeded to hunt down replacement rockers. After locating and fitting them and putting it all back together again, the engine will turn over but will not start.

So we started checking the fuel system, checking all the line and connections. Everything seemed fine but when we cranked it no fuel would come out of one of the hard lines we had off the injector. So we thought maybe there was air in the lines. Finally just to ensure fuel was going we disconnected the out line on the fuel filter and fed fuel in with a long hose and funnel. We then cranked the engine and the pump started to suck fuels rom our gravity fed line just fine, and fuel came out of the loose injected line alright. So we tightened everything up and tried to crank her up. But it was still a no go.

We have reached the end of the little we know, any assistance in understanding what else to check or what it might be would be greatly appreciated.
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Mon 2 Jan 2012 20:16
Vauxhall Zafira 2.0 tdi - 2001 Vauxhall 2.0 tdi not starting - Peter.N.

If the rockers are broken its a fair bet that the cam belt has broken, or at least slipped and put the timing out.

Edited by Peter.N. on 02/01/2012 at 20:17

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