200 tdi Tapping noise

Rebuilt 200tdi attached 2 videos 1 of first fire of engine (tappets were a little noisy but were adjusted after) 2nd video with loud tapping after 120 miles running in. Havent dived into the engine yet any ideas? I have checked the usual valve clearences and injectors timing the injection pump is leaking. No smoke good power and oil pressure. After 1st fire up no 1 tappet came loose then was tightened wondering if theres a fractured slider or roller. Sounds as if its coming from top end bottom end sounds fine.

Running as it should (you tube link)

Tapping Noise (you tube link)

Well its defo valve train related.

Great im glad you said that im going to check no 1 slide and roller see if there damaged as that rocker arm went wide open. It sounds like when you drop the roller onto a metal table or drop it on the camshaft repeatedly that sort of metallic pinging. The engine was ok for a while low speeds around town after the rocker arm was adjusted wondering if the long high speed journey opened the fracture up. Ill keep posted in case any one else has this issue.

Are you sure tappet nor come loose again
what was worn during inspection and which bits did you change for new ,is there any leakage around head gasket which I read can cause a tapping sound
perhaps run it with rocker cover off and feel each rocker for vibration

Tappets are properly adjusted no head gasket leaks everything's in order its a shame rocker no 1 came loose wide open....tap tap tap but **** happens. Full rebuild bores pistons bearings camshaft bearings etc. Ill find out tomorrow when i inspect the valve gear. Its nice to have someone else confirm what your already thinking. Thanks Lynall

Was the underside of rockers not too dented which can affect rocker setting gaps , and did you fit the valve caps

Will check the underside as well good advice yeah caps are all on and staying on during operation

Pretty sure I did check them but will double check again tomorrow

Thanks

jameslandy said:

Pretty sure I did check them but will double check again tomorrow

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Is the engine still running running atm if so get a longish screw driver & put it on the engine & onto yer ear you
might be able to identify where the noise is coming from, hard to pin point it from a vid.

So took the head off today and cylinder 1 has overheated. 2 3 and 4 are as new pretty sure the valve train was ok so either an oil jet has failed or/and top end bush as I reused the old ones they seemed fine. The injector pump was in a state leaking and filthy in the top cap actually cut out on me twice but the second time was around 70mph when after letting it settle then driving back home the tapping noise developed. Until I strip the block tomorrow im leaning on the injector pump running lean due to air or crap in the system. Spoke to an injection pump specialist and even though its a rotary it could still be delivering a lean mixture in 1 cylinder.

jameslandy said:

So took the head off today and cylinder 1 has overheated. 2 3 and 4 are as new pretty sure the valve train was ok so either an oil jet has failed or/and top end bush as I reused the old ones they seemed fine. The injector pump was in a state leaking and filthy in the top cap actually cut out on me twice but the second time was around 70mph when after letting it settle then driving back home the tapping noise developed. Until I strip the block tomorrow im leaning on the injector pump running lean due to air or crap in the system. Spoke to an injection pump specialist and even though its a rotary it could still be delivering a lean mixture in 1 cylinder.
View attachment 286887View attachment 286888

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Feck that is a real bummer.
Diesel dont work like petrol when it comes to lean mixture, if not enough fuel in that cylinder simply means it does not deliver much power compared to the other three.

Be interesting to see the piston when it is out.

I have driven a 200 on three cylinders for close to 50 miles at approx 40/50mph laying a smoke trail to make the royal navy jealous! then it chimed in on four and got me the other 80 miles home.
I put another injection pump on it to cure it, I had already tried new injectors.

So if that's the case then the injection pump could not have caused it to overheat with a lean mixture......when it did cut in and out made the engine quite rough wondering if that caused it to knock a top end out or maybe i was just running it too hard in the first 100 miles. Ill keep thinking about it until i get in the engine tomorrow. Ill keep u posted

Looks bad hopefully not too expensive, when you got it rebored did you check the end gaps in new pistons while in bore, a broken ring can sound like a tapping noise and if too tight it could cause it to partially seize, I’m at that stage on my 2286 got a 20thou oversize and new pistons but need to check all gaps.

Ive got into the guts and to be honest im relieved and ****ed off at the same time. Im relieved because i cannot find anything wrong with my work. Theres no contact with valves the oil jet was full of oil and not blocked the bolt was all good everything was tight and rotating as it should injectors were tested and working valve train working i literally cannot find anything. Now i remember measuring the cylinders accurately and 1 of them if i can remember was about 0.025 mm SP yet the tolerance given for those pistons stated 0.04 SP. Im going to try and measure as accurately as i can tomorrow. The cylinders were out of true by about 0.01mm that i can live with. 2 3 and 4 are literally like the day i put them in. There is zero play in the small end in the mains and big ends nothing. I think i will be having words with the machine shop. The engine has done 120 miles.

The little marks on the bottom of the shell are from the dial bore gauge there not scratches

All my ring gaps were checked before installed despite being told by the machine shop i wouldn't worry weve never had any come back

The ring gaps were too tight in every cylinder before adjustment

The middle ring is completely compressed to the piston

Steve check your bores accurately before u do anything do not trust the machine shop