200tdi loose cam sprocket

Good morning all, after looking into the cause of knocking from my 200 TDI engine, I have found that the bolt has come out of the camshaft sprocket. The timing case cover stopped it coming off but not before mashing the end of the camshaft. The engine will still turn over by hand but I should imagine I'm looking to replace a couple of pushrods at least , all the rockers look okay But I haven't taken off the cylinder head yet . Apart from camshaft, bearings, and new sprocket can anyone who has done this job please tell me the approximate parts list that I'm going to need including seals etc? Thanks Patrick

a lot of oil and stuff in there. seals will probably need replacing too!

Look on youtube for 200tdi and you will be able to watch a snapped belt rebuild showing all the bent broken bits. Not the same as yours but worth watching and it will show you "how to"

mojo247 said:

a lot of oil and stuff in there. seals will probably need replacing too!

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Yes came in through the cam hole!

Gmacz said:

Look on youtube for 200tdi and you will be able to watch a snapped belt rebuild showing all the bent broken bits. Not the same as yours but worth watching and it will show you "how to"

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Know the video you mean, but could'nt get it to play

That video mentioned above is Deffo worth a watch if you can get it to work.

opened it now, good video. I'm strugling to get the rear part of the timing case of due to a previously snapped bolt near the water gallery. Does any one know if the cam followers drop down when I remove the shaft?

Chadstone Pat said:

opened it now, good video. I'm strugling to get the rear part of the timing case of due to a previously snapped bolt near the water gallery. Does any one know if the cam followers drop down when I remove the shaft?

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Yes mate, I think that you can guarantee that they will drop down, after all they normally move up and down on the cam lobes, if you try to pull the cam out it will not come out if it moves out at all you will not get it back in without taking a lot of other stuff out.
Before you try pulling anything out or off just double check that the rockers are still all ok and that there are no bent push rods, it is possible there has been no collision between pistons and valves, bearing that in mind, I suggest.
Unless you want to do a whole lot of unnecessary work, depends on how absolutely fussy you are and how good the vehicle is, I would just work at replacing the sprocket bolt in the camshaft, the thread inside may require cleaning out with a tap, that will stop the oil leak, give the whole timing case insides a degrease and thorough clean, if you think the belt is fubared just replace it set up the timing/tension, all may be ok, minimal work minimal cost, maybe worth a try.
Just remember if you are going to proceed this way, to turn the engine over by hand a few turns just to convince your self all is ok inside before attempting a start.

As I thought Gazbo, I'd leave the camshaft alone but the end has been broken so it has to come out I'm afraid. pushrods have been slightly bent so I'll need new ones but the rockers and cam slides look ok, it was only on tick over when it went. Head off it is then

Good luck with the fix bud. Remember to label bits as they come off and always best to keep the cam followers in the same order that they came out in when refitting.

Chadstone Pat said:

As I thought Gazbo, I'd leave the camshaft alone but the end has been broken so it has to come out I'm afraid. pushrods have been slightly bent so I'll need new ones but the rockers and cam slides look ok, it was only on tick over when it went. Head off it is then

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head of and remove the brass slides and roller followers,you will also need to remove the vac pump ,oil filter housing(to get at the skew gear retaining screw) because that needs to come out too

Nothings ever easy, if I get a new camshaft can I leave the old bearings in? or is it worth getting a good second hand one, same with the followers should I buy new ones for a new cam? Thanks for your help all.

Chadstone Pat said:

Nothings ever easy, if I get a new camshaft can I leave the old bearings in? or is it worth getting a good second hand one, same with the followers should I buy new ones for a new cam? Thanks for your help all.

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if old bearings are good then your best leaving them , the front most bearing gets the worst wear generally but you guarantee that, you need a tool to fit new bearings and they fitting exact so oil holes line up

good, thats what I wanted to hear

well valves all seem well seated. Expected whack marks on the top of the cylinders, and ripe for a de-coke. rear part of timing case finaly came off after hacksawing a seized bolt off

Chadstone Pat said:

As I thought Gazbo, I'd leave the camshaft alone but the end has been broken so it has to come out I'm afraid. pushrods have been slightly bent so I'll need new ones but the rockers and cam slides look ok, it was only on tick over when it went. Head off it is then

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Didn't realise that the camshaft end had broken off, couldn't see that from your photos, it's a shame, but looks as if you are making reasonable progress.
Worth checking, seeing as the head is now off, the valves seating even though they may look ok.
Hope the job runs ok for you.

That cam bolt coming loose must be one of the most unusual 200tdi faults Ive ever heard of?

lynall said:

That cam bolt coming loose must be one of the most unusual 200tdi faults Ive ever heard of?

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Probably whoever changed the last belt also changed the cam seal and didn't torque the bolt up correctly afterwards.

Kwakerman said:

Probably whoever changed the last belt also changed the cam seal and didn't torque the bolt up correctly afterwards.

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yes the belt looks pretty new, worth putting a dob of thread locker on probably. Time for me to find the valve spring compressor that I have been falling over all year and has now disappeared!

Chadstone Pat said:

yes the belt looks pretty new, worth putting a dob of thread locker on probably. Time for me to find the valve spring compressor that I have been falling over all year and has now disappeared!

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Look in the last place first, bound to find it there!