200 TDI engine clatte

So, I'm on my to Wales on Thursday for a spot of laning on Friday, Saturday
and Sunday in my 200 TDI disco that I'm allowed to play in, as opposed to
the family one......

Pootling down the A14 the tappets starting sounding rattley, so decided to
pull in at the next junction, approx 1 mile away....

Suddenly, large sound like a stone hitting something and she dropped to
about 2 and 3/4 cylinders, with unburnt diesel smoke pouring out the
back..... loud clattering sound develops....:-(

Managed to limp the remaining 1/4 mile to the exit and pull up. Engine
still running but decidely poorly....

Take the rocker cover off, and was greeted by the sight of one of the tappet
adjustment screws (no.3 cylinder snapped at the point where it passes
through the rocker arm. The valve stem cap for that valve was also missing,
and could not be found....

The inlet and exhaust valve clearances for the remaining valve on no3 and
both inlet and exhaust on no 4 are miles away........

Fitted new cambelt approx 250 miles ago when engine installed, valve
clearancs checked and no adjustment required at that time. Had been tested
and proved to be a decent runner on the offroad course at driffield......

Is it likely that the tensioner has worked loose, alowed the belt to slip
and casued the damage as described? I intend dropping the sump oil tomorrow
to look at it for metal bits, and remove the timing case cover to check the
belt and its tension. Any other hints, clues etc?

Ended up going home and taking the family Disco laning, now have a lot of
polishing to do as well :-(

--
Simon Isaacs

Peterborough 4x4 Club Newsletter Editor and Webmaster
Green Lane Association (GLASS) Commercial Officer
Part owner of 1976 S3 LWT, Fully restored, ready for sale! Make me an
offer!
Suzuki SJ410 (Fiancée's) 3" lift kit fitted, body shell now restored and
mounted on chassis, waiting on a windscreen and MOT
Series 3 88" Rolling chassis...what to do next
1993 200 TDi Discovery
1994 200 TDi Discovery body sheel, being bobbed and modded.....
1979 Range Ruster body shell and chassis

"Simon Isaacs" <[email protected]> wrote in message
news:[email protected]...
> So, I'm on my to Wales on Thursday for a spot of laning on Friday,
> Saturday and Sunday in my 200 TDI disco that I'm allowed to play in, as
> opposed to the family one......
>
> Pootling down the A14 the tappets starting sounding rattley, so decided to
> pull in at the next junction, approx 1 mile away....
>
> Suddenly, large sound like a stone hitting something and she dropped to
> about 2 and 3/4 cylinders, with unburnt diesel smoke pouring out the
> back..... loud clattering sound develops....:-(
>
> Managed to limp the remaining 1/4 mile to the exit and pull up. Engine
> still running but decidely poorly....
>
> Take the rocker cover off, and was greeted by the sight of one of the
> tappet adjustment screws (no.3 cylinder snapped at the point where it
> passes through the rocker arm. The valve stem cap for that valve was also
> missing, and could not be found....
>
> The inlet and exhaust valve clearances for the remaining valve on no3 and
> both inlet and exhaust on no 4 are miles away........
>
> Fitted new cambelt approx 250 miles ago when engine installed, valve
> clearancs checked and no adjustment required at that time. Had been
> tested and proved to be a decent runner on the offroad course at
> driffield......
>
> Is it likely that the tensioner has worked loose, alowed the belt to slip
> and casued the damage as described? I intend dropping the sump oil
> tomorrow to look at it for metal bits, and remove the timing case cover to
> check the belt and its tension. Any other hints, clues etc?
>

So far have found one broken tappet screw, 8 bent pushrods. Cambelt has
not snapped, all teeth present and accounted for, and timing marks still all
line up, the tensioner is still okay, and tension as per the book.

Bit concerned, so took the head off, stripped valves to check them for
damage, none, so have reinstalled them after grinding back in with new stem
seals, springs etc. Bores are not damaged, they even have honing marks on
them... Cleaned the tops of the pistons, found evidence of valve impact,
but only it could only be seen once cleaned, so I'm now working to a theory
that the cambelt failed previously, but not all the pushrods were replaced,
only those that appeared to be bent, some look newer than others. The
failure fatigued the tappet screws which in turn began to fail, which led to
the damage that has occurred. Just got to wait for new pushrods and tappet
screw to arrive and see what happens at start up!

--
Simon Isaacs

Peterborough 4x4 Club Newsletter Editor and Webmaster
Green Lane Association (GLASS) Commercial Officer
Part owner of 1976 S3 LWT, Fully restored, ready for sale! Make me an
offer!
Suzuki SJ410 (Fiancée's) 3" lift kit fitted, body shell now restored and
mounted on chassis, waiting on a windscreen and MOT
Series 3 88" Rolling chassis...what to do next
1993 200 TDi Discovery
1994 200 TDi Discovery body sheel, being bobbed and modded.....
1979 Range Ruster body shell and chassis

"Simon Isaacs" <[email protected]> wrote in message
news:[email protected]...
>
> "Simon Isaacs" <[email protected]> wrote in message
> news:[email protected]...
> > So, I'm on my to Wales on Thursday for a spot of laning on Friday,
> > Saturday and Sunday in my 200 TDI disco that I'm allowed to play in, as
> > opposed to the family one......
> >
> > Pootling down the A14 the tappets starting sounding rattley, so decided
to
> > pull in at the next junction, approx 1 mile away....
> >
> > Suddenly, large sound like a stone hitting something and she dropped to
> > about 2 and 3/4 cylinders, with unburnt diesel smoke pouring out the
> > back..... loud clattering sound develops....:-(
> >
> > Managed to limp the remaining 1/4 mile to the exit and pull up. Engine
> > still running but decidely poorly....
> >
> > Take the rocker cover off, and was greeted by the sight of one of the
> > tappet adjustment screws (no.3 cylinder snapped at the point where it
> > passes through the rocker arm. The valve stem cap for that valve was
also
> > missing, and could not be found....
> >
> > The inlet and exhaust valve clearances for the remaining valve on no3
and
> > both inlet and exhaust on no 4 are miles away........
> >
> > Fitted new cambelt approx 250 miles ago when engine installed, valve
> > clearancs checked and no adjustment required at that time. Had been
> > tested and proved to be a decent runner on the offroad course at
> > driffield......
> >
> > Is it likely that the tensioner has worked loose, alowed the belt to
slip
> > and casued the damage as described? I intend dropping the sump oil
> > tomorrow to look at it for metal bits, and remove the timing case cover
to
> > check the belt and its tension. Any other hints, clues etc?
> >
>
> So far have found one broken tappet screw, 8 bent pushrods. Cambelt has
> not snapped, all teeth present and accounted for, and timing marks still
all
> line up, the tensioner is still okay, and tension as per the book.
>
> Bit concerned, so took the head off, stripped valves to check them for
> damage, none, so have reinstalled them after grinding back in with new
stem
> seals, springs etc. Bores are not damaged, they even have honing marks on
> them... Cleaned the tops of the pistons, found evidence of valve impact,
> but only it could only be seen once cleaned, so I'm now working to a
theory
> that the cambelt failed previously, but not all the pushrods were
replaced,
> only those that appeared to be bent, some look newer than others. The
> failure fatigued the tappet screws which in turn began to fail, which led
to
> the damage that has occurred. Just got to wait for new pushrods and
tappet
> screw to arrive and see what happens at start up!

My naD was a bit tappety and I discovered a bunch of bent pushrods when I
took the top off.
Somone must have just adjusted the slack out and left it.