discovery 300 tdi advice needed!!

mud_man said:

just a quick update , it maybe pointing to an internal crack in the head ???....looks like an engine change is on the cards

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what makes you say that?

i had some1 look at it who informed me that it is possibly a crack in the cylinder head he did say it was a strange 1 as when u hold a pole to all areas of the engine..turbo.etc etc u cant hear any knocking at all not in the big ends little ends crank area nor in the head the loudest part seems to be the back of the cylinder head ( bulkhead) and there are fumes coming from the rear of the engine somewhere but its a brand new head gasket and valves on it so far but when its revved up a bit about 3000rpm it sounds like metal on metal sort of noise proper stumped noise on 3000rpm sounds like a valve tappin the piston but how is that possible?????

mud_man said:

i had some1 look at it who informed me that it is possibly a crack in the cylinder head he did say it was a strange 1 as when u hold a pole to all areas of the engine..turbo.etc etc u cant hear any knocking at all not in the big ends little ends crank area nor in the head the loudest part seems to be the back of the cylinder head ( bulkhead) and there are fumes coming from the rear of the engine somewhere but its a brand new head gasket and valves on it so far but when its revved up a bit about 3000rpm it sounds like metal on metal sort of noise proper stumped noise on 3000rpm sounds like a valve tappin the piston but how is that possible?????

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One valve gap set wrong??

is that possible,all this started with it overheating ..after it overheated and cut out it drove home 80 miles problem free and sounded fine right up until my front door then it suddenly started to rattle and its been the same since ....any more ideas would be very welcomed as now been without wheels for 3weeks and getting desperate tohave it repaired !!!

hey all thank you for all your suggestions and help, its all sorted now we removed the head again changed and seated all valves,the knocking sound was the rocker arm it had adjusted itself and the gap was over an inch where it should have been 0.20 reset all rocker arms another new head gasket ....another probem ive noticed tho is the white wire that arms the diesel pump has been spliced and connected to another wire it goes through the bulkhead and isnt connected to anything ?????????? but it works how is that possible when that activates the fuel shut off solenoid but it turns off with the key ok so the ball bearing must still be operaring ok engine sounds better now than it did when i bought it.fingers crossed it will last !!!!!!!! thanks again all your advice and help is much appreciated.

Let me get this right you changed your head gasket and didn't check the valve clearances when you refitted the cylinder head?