Valve Clearance Issue

Downsy · Jul 12, 2017

Afternoon all,
My 2.5 NA started making clacking sounds the other day, assuming it was tappets, rocker cover off and feelers gauges out. Now, from the front, valves 2 and 5 have about 4-5mm of clearance. I'm out of adjustment on the rockers so cannot make good, though this is likely to just hide a bigger issue. Looking down the holes, the pushrods look straight (not bent enough to cause that amount of distance) so I'm assuming it is likely to be failure of the cam followers. Is this something that would go on an individual basis or would it be odd? It's looking to me to be a job of taking the head off, it there anything I could try before it coming to that?
Many thanks for your thoughts.

Downsy · Jul 12, 2017

Just taken the rocker assembly off to look at the rods, offending ones look straight. Shining a torch down the hole the tappet sliders look like they're in good condition with no signs of odd wear compared to others.

chris-the-gerbil · Jul 12, 2017

Do these engines have stem caps on them? Are these missing?

Downsy · Jul 12, 2017

Stem caps were missing and I bought a new set, still too much clearance to be adjusted out unfortunately.

chris-the-gerbil · Jul 12, 2017

Might be then that the missing stem caps have meant the stems have worn excessively. Are they missing from all valves or just these two?

Downsy · Jul 12, 2017

All the stems. The other 6 have suitable adjustment and all have equal stem heights. I'm thinking the followers have packed up.

chris-the-gerbil · Jul 12, 2017

That was going to be the next suggestion - check that the stems are proud of the top spring seat by the same amount. If they are then it's either bent or worn followers, or bent rods.

If it were me, I'd strip the entire rocker shaft off, pull all the pushrods and start measureing everything to make sure I know whats going on. It's not that big a job since you don't need to pull anything off the rocker shaft till you are ready to replace them.

Downsy · Jul 12, 2017

I've checked a suspect rod against a known good and they're both the same length unfortunately. Looks like it's going to be the followers then

chris-the-gerbil · Jul 12, 2017

I don't think they are that expensive actually only about a tenner for good ones. Sad though when I did a mates it was a special order no one had them in stock and we waited a couple of days.

jamesmartin · Jul 12, 2017

Downsy said:
Afternoon all,
My 2.5 NA started making clacking sounds the other day, assuming it was tappets, rocker cover off and feelers gauges out. Now, from the front, valves 2 and 5 have about 4-5mm of clearance. I'm out of adjustment on the rockers so cannot make good, though this is likely to just hide a bigger issue. Looking down the holes, the pushrods look straight (not bent enough to cause that amount of distance) so I'm assuming it is likely to be failure of the cam followers. Is this something that would go on an individual basis or would it be odd? It's looking to me to be a job of taking the head off, it there anything I could try before it coming to that?
Many thanks for your thoughts.

ive seen a lot fail recently can be all or just a number, seems often to be when replacement rollers have been fitted in the not too distant past.earlier engines didnt use stem caps though you can fit them

Downsy · Jul 12, 2017

That's not bad, just nervous as I've not taken a cylinder head off before so a bit outside of my comfort zone. The removal isn't the issue, it's the putting back together and it still working is what worries me.

Downsy · Jul 14, 2017

If I'm replacing the rollers, I assume britpart and landrover are not worth borthering with. Gives me the options of OEM or bearmach. Any thoughts on where my money is best spent?

jamesmartin · Jul 14, 2017

Downsy said:
If I'm replacing the rollers, I assume britpart and landrover are not worth borthering with. Gives me the options of OEM or bearmach. Any thoughts on where my money is best spent?

oem though ive doubts about them but bearmach wont be much different to britpart

chris-the-gerbil · Jul 14, 2017

Downsy said:
That's not bad, just nervous as I've not taken a cylinder head off before so a bit outside of my comfort zone. The removal isn't the issue, it's the putting back together and it still working is what worries me.

The diesel isn't really a complex engine and you don't have a turbo to worry about and it's oil connections. Just go slowly with the manifold bolts and it should be easy enough. If you can strip off the rockers and pushrods then TBH you are almost done already bar actually taking the lump off the top of the block.

Make sure you undo and tighten the head bolts in the correct sequence, pay attention to cylinder head and gasket selection and it wont be an issue.

Flossie · Jul 14, 2017

I used to leave the manifold on, something to hold onto to break the seal and lift the head up by.
They is heavy cast iron.
As Chris says, easy to work on as well.

Downsy · Jul 15, 2017

Thanks all, I'll update with what I found shortly.

Downsy · Jul 16, 2017

Do all the cam followers have concave faces? Reason being is that the tappet slider won't lift out easily so I was thinking of making a little too which allowed me to grab the cam follower and lift the whole assembly out as one.

Blackburn · Jul 17, 2017

Have you removed the tappet guide bolt from the side of engine block?

Downsy · Jul 17, 2017

Enough to clear the slider but still in there enough to retain the guide. I'm going to look at getting some decent snipe nose pliers to have a crack at it.

chris-the-gerbil · Jul 17, 2017

This may help - shows you useful pictures.

https://forums.lr4x4.com/topic/24695-reassembling-300tdi-cam-followers/

Valve Clearance Issue

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