Thanks Barry, I really appreciate all the help you are giving me on this.
To answer your questions the best I can, let me give you a recap of what happened so far:
- The cambelt had never been changed in 17 years and 125.000km
- The car was running perfectly when I took it in for the cambelt changing, but the cambelt was flush with the outside of the pulleys.
- The Cambelt, waterpump and rocker cover gasket were changed for new parts, including tensioner and bolts.
- Once changed, the belt was running even further towards the oustide of the pulleys, overhanging by a few mm.
- The crankshaft pulley was changed for a new one, this solved the issue of the belt overhanging although it still runs flush with the outside of the pulleys.
- Once the car was put back together, upon testing the car, it ran fine until approx 4k rpm, where it started to stutter. The dash rev counter has also stopped working.
- While test driving the car with the diagnostic machine plugged in, the machin read revs ok, and at around 3900rm was when power started to die. The machine did not report any errors.
- The engine was dismounted again, the timing was checked and is fine. The engine was turned twice by hand and the timing is still spot on, this process was repeated at least 10 times, with no variation in the timing.
- The engine was put back together again and tested (this time without my presence) and the mechanic reported that it ran fine when cold, with the VCT kicking in at around 4k rpm, but once the engine was warm, it went back to losing power at around 4k.
- The mechanic let the car go cold and tested again, getting the same results.
- The mechanic has spoked to at least 15 other people (from Ford and other places) and noone has any idea.
- His plan is to test the oil pressure at the VCT tommorow.
Unfortunately that is where we stand.
You mentioned the solenoid, which after investigating a little, seems like it can be an issue after removing the rocker cover gasket, if this has not been changed in a long time. However, I also read that this shows a fault on the diagnostic machine, which is not showing. I have seen that Ian G has a solenoid for sale on ebay for about 37 pounds (which is a hell of a lot cheaper than new), which I could purchase and try if that may be the case.
At this point I am completely lost. My mechanical partner (not the mechanic working on the car) is also of no use as he has never worked on a VCT, and he has no access to the car as it is in the garage.
Again, I really appreciate your help, and that of any one else who can offer any ideas.