SimonFromCustomerService Posted August 2, 2020 Share Posted August 2, 2020 So a couple of weeks ago, I was driving to work in my '97 300tdi defender and there was a thud and the engine came to a stop. And I immediately knew what had happened... So after getting towed back home, I decided to take the job on myself and try and fix her up. Over the last few weeks I've been ordering various parts and tools and have slowly been getting there. And Today I thought I would be done. I got the engine all re-timed up (at least I think I have) The wood ruff key was at 12 o'clock to the arrow and the timing pin was in the bell housing. The Injector pump had the locking pin in it. And the camshaft sprocket was aligned with the marking on the sprocket and the casing. Everything was torqued to spec and I re-did all the valve clearances after putting the new push rods and rocker shaft back in. (btw all the cam followers were in great shape and not cracked) I went to start her a few hours ago and it started fine but it seems to "chug", I did take the radiator/ intercooler and oil cooler off. I'm assuming the chugging is low oil pressure or the intercooler not being connected? I've linked a video below: and would love to hear what you guys think. Cheers. https://drive.google.com/file/d/1Taevy3CObC6Hu0Vlt5fR29gusiVal6ev/view?usp=sharing Quote Link to comment Share on other sites More sharing options...
Gazzar Posted August 2, 2020 Share Posted August 2, 2020 What did you check on the valves? Push rods okay? Quote Link to comment Share on other sites More sharing options...
SimonFromCustomerService Posted August 2, 2020 Author Share Posted August 2, 2020 Just taken the rocker cover off again and the push rods are all fine. But a couple of the rockers are really floppy. (really out of adjustment) You think it would cause the chugging noise? Surely if the engine was out of time it would have destroyed itself again? Think I'm going to have to re adjust the tappets and then put the radiator back in, so we have a oil cooler ect. Will keep you posted. Quote Link to comment Share on other sites More sharing options...
Happyoldgit Posted August 2, 2020 Share Posted August 2, 2020 If I were you I would stop right there! For starters you really do need to check the pushrods and valve gear properly ...and not just a visual check in situ. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted August 2, 2020 Share Posted August 2, 2020 Yes, any bent valves? Piston damage? Also, how are you able to run the engine without the oil cooler? Have you a by-pass? There's valves and thermostats in the filter housing that redirects the oil when hot. Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted August 2, 2020 Share Posted August 2, 2020 Quite possible you just naffed up the valve clearances, happens to us all at times Quote Link to comment Share on other sites More sharing options...
steve b Posted August 2, 2020 Share Posted August 2, 2020 Are all the lash caps in place on the valves and intact ? If so re-do tappet clearances and try it again , you could well have tight clearances as well as the loose ones . Check the rocker shaft posts are located and fully seated too . Let us know how it goes cheers Steve b Quote Link to comment Share on other sites More sharing options...
smallfry Posted August 2, 2020 Share Posted August 2, 2020 Does the 300 have thrust buttons on top of the valve stems ? If so, are they all there ? Quote Link to comment Share on other sites More sharing options...
western Posted August 2, 2020 Share Posted August 2, 2020 39 minutes ago, smallfry said: Does the 300 have thrust buttons on top of the valve stems ? If so, are they all there ? Valve caps Yes on both Tdi variants. Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted August 2, 2020 Share Posted August 2, 2020 Also check the rocker shaft studs in the head for stripped threads and carefully inspect (ie remove and inspect) the rocker shaft for fractures. Mo Quote Link to comment Share on other sites More sharing options...
western Posted August 14, 2020 Share Posted August 14, 2020 Simon, please read & respond the the PM you were sent on 2 Aug. Quote Link to comment Share on other sites More sharing options...
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