Rocker shaft gave up the ghost

Haven't posted for a while after moving house, wife having a baby, and my Disco behaving itself. Until Monday when around half a mile from home something went bang. Pictures below show the culprit. Meet the new compact rocker shaft that comes in four pieces! Looks like one of the centre bolt threads had pulled out causing a bit of Shake rattle and roll.

Have stuck an M8 helicoil in, new rocker shaft, four new push rods, eight tappet screws and nuts and three cover bushes. It runs fine now, except I now notice a faint beating noise from the air box, and I have no idea if this is normal, as I can't remember if it did it before. just a quick question to any 300tdi EDC owners out there. Do you hear a noise such as this on yours, as I don't know anyone who has a similar vehicle. Also on squeezing the top intercooler hose, (after market following EGR removal) I can feel a pulsing in the hose. Again can anyone confirm this is normal or not please? Last thing I want is another breakdown especially on the M11 which is where I'm heading tonight!

Thanks in advance,
Andy

Just an update. I opened the air box whilst at tickover and the noise gets louder. It's like a sort of Pom pom pom pom noise like air beating.

sounds like a valve problem, are all tappets adjusted correctly, does the adjusters have similar amount of thread above the lock nut ,did you check followers

Hi James,
When it went back together it was all checked and double checked. I'm hoping another thread hasn't stripped out. I'll have to re-check it again in the garage at work tonight. Just as an aside. Should there be any noise from the air box? Wife thinks I'm paranoid as she has had a listen and thinks it sounds normal. I just don't remember hearing it before and thought it would be a constant sucking noise lol. I've also found the manifold gasket has obviously gone as I have a slight dribble of oil down the side of the engine. Could this have anything to do with it I wonder? Knowing my luck the heads gone, although the coolant hoses are nice and soft, no smoke etc

your noise sounds like an un-opening valve or a unsealing one

Bugger! That's a pain. It runs ok at the moment, compared to when the shaft went! Back to it in the morning then to try to work out why. Thanks for the input James. I guess the disco was bound to give me grief sooner or later ��

jamesmartin said:

your noise sounds like an un-opening valve or a unsealing one

Click to expand...

Just a quick update. The tappets were re-checked, and one of the little top hat shims was missing. It was definitely there when the rocker shaft was replaced.
Another shim put in and it's running lovely.

Question now is why and how did the shim fall off? I've not been able to find it so far, so no doubt it's found a corner to sit in somewhere under the cover.

Hopefully this one will stay in place. If not, I'm guessing the cam and followers could be suspects??

Landrovernewbie said:

Just a quick update. The tappets were re-checked, and one of the little top hat shims was missing. It was definitely there when the rocker shaft was replaced.
Another shim put in and it's running lovely.

Question now is why and how did the shim fall off? I've not been able to find it so far, so no doubt it's found a corner to sit in somewhere under the cover.

Hopefully this one will stay in place. If not, I'm guessing the cam and followers could be suspects??

Click to expand...

was a not fully opening valve then, the caps wear and break up or tappet adjustment was too large, if you cant find it it will have dropped into cam gallery

Had the same problem with a stud pulled out

The factory only gives 12mm of stud for a 25mm hole in the head!

I stripped ours down and made full depth studs, also made them longer and used regular nuts atop the valve cover so I could check the studs werent spinning whilst torquing the valve cover down

Our rocker shaft was in 2 pieces, I just put it back in, it's been reet for 18 months