200Tdi - No.8 Valve Pushrod snapped twice in as many days....!!!

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Saint.V8

Dyed-in-the-wool 100% RR Junkie
Full Member
As title....

Monday, girlfriend phoned and said she hard a bang, then the engine lost all power and was popping and chuffing.....

Recovered home and I whipped the rocker cover off to find no.8 pushrod snapped....

Had spares as was going to do a top end overhaul with new valve seals, guides, rods etc....so I fitted all new pushrods, regapped the clearances and took it for a test drive, a little knocky, but not bad.

Tuesday, went to time the fuel pump (have the timing pins and flywheel pin etc) but noticed that with the flywheel pinned and at TDC, even without loosening the 3 pulley adjustment bolts, it is possible to turn the pump pulley using the large nut by almost an 1/8th of a turn..!!!

Any-hoo, retimed as best I could considering this excessive movement.

Took it for a drive and she was alright once she had been left to run for 20 seconds before moving off (hmmmmm), smokey (hmmmmm), but after 5 minutes she was fine albeit a tad knocky and noisy.

Was getting late by this time so I parked her up and went to bed.

Girlfriend took it to work Wednesday and she noted it was a bit sluggish initially but after a few minutes was OK.

On the way home in the evening she calls me again and said it suddenly lost power and started the popping and chuffing again!

So it was recovered home last night and I have just had the Rocker Cover off just to have a peek-a-boo and the No.8 valve pushrod has snapped in half again??????????????????????????

Time for further investigation....if the fuel timing is out causing ignition before the valve has fully closed, could the combustion forces the valve closed and snap the rod....??

Thoughts chaps and chapettes?
 
Sounds like your timing belt tensioner has slipped and the belt is loose. If the crank is truly pinned at TDC and you can move the pump pulley than the cam pulley can also move and the timing will be out. I'd get the front cover off for a start and see what's gone wrong. Worth changing the belt / tensioner just in case the belt has been weakened. Also look down tappet hole to see if there is any damage to the follower. My guess is that the loose belt is the cause.
 
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