WTF has happened to my injun?

Trewey · Jan 7, 2015

OK, here's the story so far.
Under heavy load there was a sudden loss of power, accompanied by a puff of black smoke from the exhaust and the engine died.
Attempting to re-start indicated no compression.
Looking through the oil filler, valves were still going up and down whilst cranking.
Whipping off the rocker cover 8 bent pushrods could be seen.
Lots of oil in the separator and more than normal in the turbo / air cleaner.
Front cover off and cam belt is perfect - no sign of damage / slippage, tension is good, tensioner looks good / spins freely. BUT Camshaft sprocket is 90 degrees out!
Rocker shaft out, cam belt off. push rods out and cam seems to turn OK by hand and all the followers go up and down as expected.
New cam-belt, tensioner and pushrods, set timing, adjust valve clearances and fire her up.
Running on 3, breathing heavily on #4. Pressure in crank case.

Head off and gasket blown big-time on #4 between the cylinder and the oilway near the pushrod.

I can't think how the HG failure and the cam / pushrod scenario connect, but one must have somehow caused the other.

Any injun eggspurts who can explain for me?
I is confoosed!!!

fanatic · Jan 7, 2015

Trewey said:
OK, here's the story so far.
Under heavy load there was a sudden loss of power, accompanied by a puff of black smoke from the exhaust and the engine died.
Attempting to re-start indicated no compression.
Looking through the oil filler, valves were still going up and down whilst cranking.
Whipping off the rocker cover 8 bent pushrods could be seen.
Lots of oil in the separator and more than normal in the turbo / air cleaner.
Front cover off and cam belt is perfect - no sign of damage / slippage, tension is good, tensioner looks good / spins freely. BUT Camshaft sprocket is 90 degrees out!
Rocker shaft out, cam belt off. push rods out and cam seems to turn OK by hand and all the followers go up and down as expected.
New cam-belt, tensioner and pushrods, set timing, adjust valve clearances and fire her up.
Running on 3, breathing heavily on #4. Pressure in crank case.

Head off and gasket blown big-time on #4 between the cylinder and the oilway near the pushrod.

I can't think how the HG failure and the cam / pushrod scenario connect, but one must have somehow caused the other.

Any injun eggspurts who can explain for me?
I is confoosed!!!

If you got it hot it is possible that cam seized in bearings, typically on over head cam engines, not overhead valve

Trewey · Jan 7, 2015

fanatic said:
If you got it hot it is possible that cam seized in bearings, typically on over head cam engines, not overhead valve

Shirley there would have been some damage to the cam belt in that case? It's like new!

fanatic · Jan 7, 2015

Trewey said:
Shirley there would have been some damage to the cam belt in that case? It's like new!

I've seen oil cooked by cylinder gases, I'd check the pulley hasn't spun on cam and cam bearing and faces.
Either that or it jumped a tooth

Trewey · Jan 7, 2015

fanatic said:
I've seen oil cooked by cylinder gases, I'd check the pulley hasn't spun on cam and cam bearing and faces.
Either that or it jumped a tooth

Would've needed to jump a dozen teeth to be 90 deg out!

jamesmartin · Jan 7, 2015

is that 90 degrees with pump pin and flywheel pin in

The Mad Hat Man · Jan 7, 2015

I gather the camshaft carrier is prone to breaking - that could have allowed the cam to tip and then jump.... long shot , but worth checking the carriers.

jamesmartin · Jan 7, 2015

The Mad Hat Man said:
I gather the camshaft carrier is prone to breaking - that could have allowed the cam to tip and then jump.... long shot , but worth checking the carriers.

rocker shaft on a tdi

fanatic · Jan 7, 2015

Or the keyway gone on crank

Trewey · Jan 7, 2015

jamesmartin said:
is that 90 degrees with pump pin and flywheel pin in

Yes!

Trewey · Jan 7, 2015

Apart from the breathing / running on 3 cylinders, due to the HG gone, it was running OK after re-setting the timing.

Trewey · Jan 7, 2015

fanatic said:
Or the keyway gone on crank

Looks OK, as does the cam sprocket bolt (factory yellow paint still untouched).

fanatic · Jan 7, 2015

Trewey said:
Looks OK, as does the cam sprocket bolt (factory yellow paint still untouched).

Have you actually looked at crank cambelt drive pulley and keyway.

Trewey · Jan 7, 2015

fanatic said:
Have you actually looked at crank cambelt drive pulley and keyway.

Yes, all good.
Somehow the belt has "jumped", without any damage and whilst being correctly tensioned.

Trewey · Jan 9, 2015

More bad news.
There's a 4 thou divot in the surface of the head, where the gasket had been blowing, so it will need skimming.
No 4 injector is siezed solid in the head and will have to be destroyed to get it out.

Woe is me.

boguing · Jan 11, 2015

I think that you may have lost a lot of oil pressure due to the gasket failure, and that you have had a seized camshaft. If that's right, then you're going to have to look at other bearings too.

WTF has happened to my injun?

Trewey

Cockernee, Pasty munchin bastid.

fanatic

RESPECT IS EARNED, BEATINGS ARE FREE ;-)

Trewey

Cockernee, Pasty munchin bastid.

fanatic

RESPECT IS EARNED, BEATINGS ARE FREE ;-)

Trewey

Cockernee, Pasty munchin bastid.

jamesmartin

Well-Known Member

The Mad Hat Man

Well-Known Member

jamesmartin

Well-Known Member

fanatic

RESPECT IS EARNED, BEATINGS ARE FREE ;-)

Trewey

Cockernee, Pasty munchin bastid.

Trewey

Cockernee, Pasty munchin bastid.

Trewey

Cockernee, Pasty munchin bastid.

fanatic

RESPECT IS EARNED, BEATINGS ARE FREE ;-)

Trewey

Cockernee, Pasty munchin bastid.

Trewey

Cockernee, Pasty munchin bastid.

boguing

Well-Known Member

Similar threads