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My understanding on this is that if you take out the vacuum pump with the gear, and put the same one back in, then the teeth should be aligned to the same ones on the cam that they were with previously. This is because as they wear together over time, the wear is uneven and you want to match...

After much trouble with my camshaft, this flat spot on the front journal became the least of my worries. But I think I have to agree that it may be intentional to allow oil flow, as you mention. I see no way that it could have happened from wear since it is so tight against the bearing and it...

No “joy” as yet. Was hoping to tear it down to find the one part that needed replacing to fix the issue. As life is always more complicated than planned, I found loads of problems on this low mileage rebuild, as detailed over in the other post. I suspect the root of the “ticking noise” were...

Yeah, I thought about that too. But the gouges on the bearing are perpendicular to the direction of the camshaft journal travel

lynall: actually your suspicion is right on. The bearing has some gouges in it (no, I didn’t do it while pulling out the camshaft). But I don’t know how this would have caused a flat spot. Wimblowdriver: that is as good of an explanation as I’ve heard. Now, the flat spots on the #1 cam...

Not being as experienced as most on this board, I have a question about my camshaft that I just removed and will be replacing for other reasons. I found that the journal at the front of the shaft had a flat spot ash shown in the picture below. My assumption is that it's not supposed to be like...

Digging into this engine in search of the ticking noise, I removed the vac pump, oil pump and drive gear that mates with the camshaft. I noticed that some of the teeth on the camshaft were broken off the edges. This led me to tear down to get the cam out. In doing so, I found: (1) the cam had a...

Brilliant idea, I will update that thread for what I know now and later when it’s reassembled (or junked). lynall, the all-knowing. ;) Thank you for the help!

Interesting theory, the stuck follower. I should know better on mine when I am able to get all the replacement parts. Here’s a video of my ticking noise.

Must be the mysterious 200TDI “Tap-gate” issue. Just found some flat spots on a cam follower roller and a flat spot on the camshaft where it fits into the front bearing. I’m convinced that’s the cause of my tapping noise.

I would love to know if you ever solved this issue. I have an almost identical problem. I have just removed the camshaft and found some issues. Thanks!

I think you are right about the oil pump drive shaft. I discovered last night that the metal chunks (pic below) came from a fragmented skew gear on the camshaft (video below). Looks like I'm in for a big job! Wish I knew what caused this. Any ideas?

Great, thank you all. Now to find what is broken and the source of the metal bits/chunks in the engine.

In my quest to solve the ticking problem in my 200TDI with only 5,700 miles, I pulled the oil sump (except for the 2 bolts that decided to leave half of themselves in the block), pulled the oil pump and its drive shaft. Started to notice some metal bits in sump and other places, NOT GOOD! So...

Injector washer I can easily handle. Head gasket would be a nightmare, but I will prevail over this engine. Hand to be dutifully inserted when the sun comes up. Many thanks.

I did notice the vac pump hose was wearing on the engine pull hook. I have a new one on order. I will try the medical doctor method. Thank you!

I have not yet tried the injectors, waiting on an order of copper washers, they are not readily available in these parts. Do you mean crack them off while it’s running? Sounds kind of dangerous. Hoping your latter suspicion is not the case! Thank you!

I've posted before about this issue thinking it was different parts, just can't figure it out. I've: adjusted valves and replaced cover gasket, verified no leak in vac pump lines and replaced the fuel lift pump. The noise started after a 600 mile run in 12 hours at about 65-70mph. This was...

Interesting. I had a mechanic tell me he thought I was having blow by. But your comment makes me think it may be excess block pressure from a vac pump sucking air continuously. That’s awesome and I’ll try the plug thing.

Thank you. Manifold gasket just made the list!