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hi caulky,..........your motor is hard to start and has smoke when it starts as the injection pump timing needs adjustment,the engine of yours i know has a brand new belt on and your timing is slightly out,a di should start first turn of the key.............you need a timing pin kit to check it or you can use drills............you need to take of the front and rad,remove the fan and a pully wheel,unbolt and remove the black plastic timing case cover........ disconnect the battery..........locate your biggest timing pin in the kit........look under the fuel filter head on you will see a hole it may well have a grey plastic plug in it,if so remove........put the pin in hear,turn the crank with the 36mm socket or spanner and as you do apply pressure to the pin you will fell it slip in...............now look at your camshaft sprocket you should be able to slip one of the smaller pins in here..............now look at the injection pump you should be able to  fit a pin in here to....................the injection pump as 3 0r 4  13mm bolts holding the sprocket on,you can loosen them and advance and retard the timing a nats wisker at a time useing a 22mm swan neck spanner or a socket , yopu will know when you have it spot on as the engine will run smothly,tick over well,there will hardly a puff of smoke on starting,the engine noise will be reduced,and ther will be a noticable increase in aceleration ................the garage should of set it up for you ,sounds like they have just chucked the lump in for you,or just could,nt be bothered to do it........................if you need the lend of some pins i will post you a set over best wishes billy in brum ............  :-)

morning dave (caulky).........thats the spirit mate soldier on you will get there in the end ,the motor looks very tidy in yout pics, ......keep your chin up best wishes billy in brum :-)

hi,

     did you get the overheating sorted, don,t know if the tranny has the same cooling system as the fiesta or the escort ,but they had a problem with the small return pipe leading back to the header tank getting blocked ,causing an air lock leading to overheating

                            mick

hi dave (caulky) you hit the nail smack on the head there sir......the early mk2 heaters with a 2.4  in where next to useless...........ford fitted a much better heater in the transit mk 2 face lifts,.............the same heater but with different controls was fitted to mk3 transits ,...............the heat out put is 10 fold better,the early mk2 has a small matrix and rust collects in it,and no matter how many times you wash it thro its still poor, ..............you can put a later mk 2 heater in but you have  get someone to cut the metal support frame out in the cab after removing the early heater..............you then line up the later heater drill some holes thro the bulk head for some 2 1/2inch nuts n bolts x4 (useing holes in later heaterbox frame )..............put some sealant round the facing edge to bulk head and bolt in,needs a mate in engine bay to hold nuts or a pair of mole grips does the job,............. i have put later heaters in janets mk2 and tonys mk 2 , the motors are fairly simple to change to should they pack in compared to the early heaters,............some times tho its only down to a corroded fuse in the fuse box as there not the best of fuse boxes ,puting card in front of the rad, putting a hotter thermostat,removing the fan all makes no diffrence to the early heaters..........you must keep antifreeze in your di all year as if you dont the water rusts up and attacks the headgasket etc.........  very best wishes billy in brum :-).....................................................................................................mk 3 heaterboxs to do a conversion are ready available  from the breakers here in brum at £25