Allen's ROW
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MY DEEFENDER IS EATING VALVE CAPS - Help!
Please, any help would be appreciated - here's the thing.
I have a 110 Defender Station Wagon on and 03 Plate BUT IT IS A ROW SPEC, so 300Tdi Engine and Chassis, No CAT, TD5 Loom, Axles, Bodywork etc.
Its been a dream until - 56k did a Cam Belt - all OK, but 6 months and 4k later (so 60k) she developed a tinny clatter on retard - so as you excellerate and then come off the throttle there was a rattle that reduced as the rev's did. Asked my garage, told to come in when convenient and they'd adjust the tappits. 2 days later, rattle suddenly became real loud - all stop, rocker guide rail sheared in 2 places.
Rocker cover off, new guide rail, found 7 worn valve caps, 1 missing in action. Camera down the value pots - no sign, looked for it everywhere but didn't drop the sump (cause of the axle clearance and my southdown axle guard etc), changed the oil and filter, reset the tappits to 0.02mm and off we go.
1.5k miles later - rattly again. Regapped tappits - 0.02mm on stone cold engine. OK for a while then rattling and harsh sounding. 65k did the timing, retarded her a touch - less harsh but still rattling.
70k (and 15 months after guide rail incident) - rattling increasing, service due so we go looking for problems. Checked timing AOK, Checked inlet manifold and exhaust for shot gasket, lost stud - AOK, smoke filled engine, check the stroke, rings etc AOK, lifted the rocker guide rail/arm assembly - found 1 value cap 50% worn through, other showing severe signs of damage - 10k since they were replaced. Inspect all rocker arms, no wear, look AOK, retract push rods, look for wear at bottom, where they sit in the cam followers - no wear. Pushrods look true, not bent or warped. In general there is no swarf anywhere, there is no shards in the sump plug magnet.
So we do 8 New valve caps (all genuine dealer parts) and reset tappits to 0.02mm - no rattle, running lovely.
72k - Rattling again - after 2 weeks and a 2k trip to wales on holiday. Rattling on retard as you come off the throttle, about 2500 - 3000 revs I guess, can hold the rattle on with careful throttle control, noise comes through the bulkhead around knee height on passenger side - even the wife can hear it!!!!
ANY IDEAS???? Gonna regap the tappits tomorrow and look for correlation on which one is baggy (3 was the worst last time), maybe switch the rocker arms around on the rail and see if the bagginess moves with the rocker arm, plan to inspect the threads on the studs to see if the rockers are coming loose.
I've had some suggestions - Its a ROW spec, going to a hot country, engine set up with larger clearances - Ask for ROW spec clearances from LR???, Change all the rocker arms?? change the cam shaft and cams?? - but hold on!!
Thanks - Allen
I have a 110 Defender Station Wagon on and 03 Plate BUT IT IS A ROW SPEC, so 300Tdi Engine and Chassis, No CAT, TD5 Loom, Axles, Bodywork etc.
Its been a dream until - 56k did a Cam Belt - all OK, but 6 months and 4k later (so 60k) she developed a tinny clatter on retard - so as you excellerate and then come off the throttle there was a rattle that reduced as the rev's did. Asked my garage, told to come in when convenient and they'd adjust the tappits. 2 days later, rattle suddenly became real loud - all stop, rocker guide rail sheared in 2 places.
Rocker cover off, new guide rail, found 7 worn valve caps, 1 missing in action. Camera down the value pots - no sign, looked for it everywhere but didn't drop the sump (cause of the axle clearance and my southdown axle guard etc), changed the oil and filter, reset the tappits to 0.02mm and off we go.
1.5k miles later - rattly again. Regapped tappits - 0.02mm on stone cold engine. OK for a while then rattling and harsh sounding. 65k did the timing, retarded her a touch - less harsh but still rattling.
70k (and 15 months after guide rail incident) - rattling increasing, service due so we go looking for problems. Checked timing AOK, Checked inlet manifold and exhaust for shot gasket, lost stud - AOK, smoke filled engine, check the stroke, rings etc AOK, lifted the rocker guide rail/arm assembly - found 1 value cap 50% worn through, other showing severe signs of damage - 10k since they were replaced. Inspect all rocker arms, no wear, look AOK, retract push rods, look for wear at bottom, where they sit in the cam followers - no wear. Pushrods look true, not bent or warped. In general there is no swarf anywhere, there is no shards in the sump plug magnet.
So we do 8 New valve caps (all genuine dealer parts) and reset tappits to 0.02mm - no rattle, running lovely.
72k - Rattling again - after 2 weeks and a 2k trip to wales on holiday. Rattling on retard as you come off the throttle, about 2500 - 3000 revs I guess, can hold the rattle on with careful throttle control, noise comes through the bulkhead around knee height on passenger side - even the wife can hear it!!!!
ANY IDEAS???? Gonna regap the tappits tomorrow and look for correlation on which one is baggy (3 was the worst last time), maybe switch the rocker arms around on the rail and see if the bagginess moves with the rocker arm, plan to inspect the threads on the studs to see if the rockers are coming loose.
I've had some suggestions - Its a ROW spec, going to a hot country, engine set up with larger clearances - Ask for ROW spec clearances from LR???, Change all the rocker arms?? change the cam shaft and cams?? - but hold on!!
Thanks - Allen
