2.5TDI rattle

[Jmac]

Down on power not so good, have a compression test done to at least pinpoint the cylinder, if power was ok i would have pointed you to the exhauster pump for the brakes driven off the camshaft but sounds deeper than that, doesnt sound DMF at all mate.

Diesel compression tester also requires adapter for the job too, and you should expect around 360psi- 450psi so yeah a normal tester will hit the roof.
Jmac

[jets]

[QUOTE=t4 camper;309958]
I tried to check valve clearance but found cam direct on buckets.
How is the valve clearance checked?QUOTE]

Your engine has hydraulic lifters, so no need to check clearance.

[t4 camper]

Thanks for all the help.
Dropped the vacuum pump and pulled the cam follower this morning.
Noise is still there.
Thanks Jets, solved that query.

Time for professional help.
Neil

[t4 camper]

Had arranged to meet Jmac for a professional diagnoses on Sunday,
set off to meet him and rattle got louder in a hurry, just got back home.
Definately from top rear of engine, still thought was turbo.
Pulled out turbo and manifolds tonight, all OK.
Take rocker cover off again.
Find some spare bits floating around.


tops from cam followers #2 & #3


So next is off with it's head.

Any recomendations for head repair on Sunshine Coast or Brisbane?
Also gaskets and cam followers/parts.
Hope the valves and pistons have not had an untimely meeting.
Neil.

[BrianJ]

I don't understand what has happened there, isn't the trouble external in the rocker area, why do you need to take the head off as the vales should have opened less, so could not hit the pistons.

Or have I got this all wrong.

Brian

[t4 camper]

Thanks Brian,
It's not off yet, I expect I will need to take it off as there is some damage to the cam bucket bores at the top where bits have hit down.
I will have to take the cam out to replace followers.
I am reading at present to work out how to lock the injection pump in place whilst taking the cam out.
If I can clean up the cam bores enough I my try it, hopefully the valves have not been jammed down and whacked by the piston top.

Neil

[t4 camper]

Found the cause of the problem and the extent of damage.
The cause is a failed timing belt tensioner, and the valve timing is out, late.
All five intakes have hit the pistons, 2 intakes have broken cam buckets as shown.
Bent valves, are also obvious, not sure about valve guides, the cam shaft is damaged from impact with the broken buckets, but not broken into pieces, which I have been told is the common result when belt breaks.
The cam belt and tensioners were replaced at 120K just on 12 months ago, now 147K.
Don't know if I have any recourse with the tensioner supplier or installer.

I can see an expensive week ahead.
Thanks for the help in the diagnosis.
Neil

[Jmac]

Geez mate not so good. Failed tensioner (new) not good at all, what make and where is it from????????
Jmac

[BrianJ]

That's really bad luck.

I thought all 2.5 TDI had chains and chain tensioners for cam drive, is yours a 5 cyl or 4 cyl

Brian

[jets]

The cam belt and tensioners were replaced at 120K just on 12 months ago, now 147K.

I wonder if the tensioner was actually changed. I read on a UK forum where a water pump had failed, leaking water all over the place. The owner had paid for the pump to be replaced at the last cam belt change some 3 months earlier. The garage quickly offered to replace it at no cost. It was obvious from the photo that he posted that the pump was old & discoloured & infact had not been replaced. Unfortunately not all garages are honest.