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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

 

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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.  

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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.

 

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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

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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.

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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

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