Ford Transit 2.2 TDCi rattles on startup - stretched timing chain

A metallic rattle lasting one or two seconds after a cold start is a classic sign of timing chain wear on a Transit 2.2 TDCi. This engine was fitted from 2006 to 2016 in the MK7, early MK8 and Transit Custom. Its basic design is the same in all of them, so the problem can occur regardless of the generation. The chain tensioner relies on oil pressure, while the nylon guides wear over time. After the engine is switched off, the chain hangs loose and rattles on the next startup until oil pressure extends the tensioner. Another characteristic early warning is that the engine starts “on the second attempt”: it fails to fire when the key is turned the first time but starts on the next attempt. At an advanced stage, misfires and camshaft-to-crankshaft correlation faults appear. If the chain is neglected, it can eventually break and damage the rocker arms.

When should the 2.2 TDCi timing chain be replaced, and what causes it to fail?

Ford specifies no replacement interval for this chain, and with good servicing it can indeed last 300,000-500,000 km. Oil is the chain's main enemy: using the wrong viscosity, as the engine requires 5W-30, or extending oil change intervals reduces pressure at the tensioner and starts a chain reaction of wear. The same story repeatedly appears on owners' forums: the rattle begins a few thousand kilometres after a service with unsuitable oil. The complete kit must be replaced, including the chain, tensioner and guides. Fitting only a new tensioner with worn guides provides no more than temporary quiet. Before condemning the timing chain, distinguish startup rattle from cold injector knock or a loose injector clamp, as both can sound similar on this engine.