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Thread: 300Tdi death rattle?

  1. #1
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    300Tdi death rattle?

    Hi All,

    Quite some time ago I replaced the head gasket after a blown gasket/overheating episode. A local bloke machined the head flat again (~18 thou') and the engine runs well with normal power levels but ever since it's had this horrible clatter, especially when cold. Gets quieter when fully warmed-up. I have checked the valve lash caps and clearances several times.

    A couple of weeks back I again removed the rocker shaft and examined the push rods and - yoo-hoo - found the no.2 inlet rod had a slight bend. Maybe this is the problem? All the others are straight. So, I order a replacement from Roverlord (usual excellent service!) and fitted it. And rechecked the valve clearances. And started up the engine. And Bugga! - the clatter is still there.

    I'm sure the noise is related to a single cylinder and is in the valve gear somewhere. I've separately cracked each injector pipe and all caused the same drop in idle rpm but made no difference to the clatter. Is it possible the problem is deeper down the push rod holes - broken or cracked cam follower for example?

    I've attached an audio file from my phone. All suggestions gratefully received. Thank you.

    300Tdi engine noise 2.wma
    Last edited by Leo109; 8th February 2021 at 05:17 PM. Reason: Fixed title
    Ian &
    Leo - SIII 109/GMH3.3
    Daphne I - '97 Disco 300Tdi Manual
    Daphne II - '03 Disco Td5 Auto

  2. #2
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    A common cause for clatter in the tdi could be the vacuum pump.

    I've had personal experience myself with clatter from the serpentine belt tensioner. Sounded like big or small end bearing or something like that.

    Don't assume that just because you fixed something up, this noise could be as a result of that work done. You may have disturbed something else and caused the issue.
    Arthur.

    '99 D1 300Tdi Auto
    '03 D2 Td5 Auto

  3. #3
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    Hi Arthur,

    Thanks for the suggestions. Nup, not the vacuum pump. (That's been gone for a decade or so, replaced with an electric VP.)

    Hmmm, serpentine belt tensioner. Yes, it was replaced (also about a decade alone). At that time the symptoms were a belt squeal that couldn't be silenced. But thank you, I'll check it out.
    Ian &
    Leo - SIII 109/GMH3.3
    Daphne I - '97 Disco 300Tdi Manual
    Daphne II - '03 Disco Td5 Auto

  4. #4
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    I spent a lot of time and money trying to find and eliminate a rattle. It was the clutch spring. It was nearly impossible to accurately find where the noise was coming from.

    Clutch Plate Faults - When a rattle is clutch plate springs and not a gearbox fault. - YouTube
    1996 Disco 1 300TDI manual - Lucille a cantankerous red head! :D
    1997 Disco 1 300TDI Auto - sold

  5. #5
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    Like BathurstTom, noises come from anywhere, at random times, and seemingly begin immediately after some non related work has been done.

    With my tensioner problem(I think I suffered it for a good 6 or more months) .. was after a routine service, belt looked a bit worn, so renewed(and another new spare bought) ...

    Anyhow, turned out that they're just a bit longer than supposed to be(Gates), and it would 'top out' the tensioner, and the tensioner would 'clack'. Dunno how I noticed it tapping at it's extreme end, which coincided with the actual noise .. but it had to be found eventually.
    I got a Continental belt that wasn't Continental(got a 50% refund) but was another Gates, but very different to all the other Gates easily got from any store locally. Compared to the new one I had as spare and for sure slightly less length, even tho they're supposed to be the same size (7PK1580) .. they all say the same thing on the package!

    Anyhow, the reason it clacked is a bit more complicated than just the belt being a bit longer than it should be, it's actually that my replacement water pump seems to be not 100% round(circular) at the flange. I thought it was the pulley, so got a new one but same thing. I have about 1-2mm of out or roundedness at the pulley which causes the tensioner to vibrate more than it otherwise would .. hence the longer belt caused it to top itself out on it's bump stop.

    Actually thanks for the reminder .. been meaning to replace waterpump, but it gets forgotten (now that the belt stops the tensioner from clacking! )


    .. off to chase up a new waterpump.

    EDIT: sorry forgot to say, yours is probably not the same issues as what I had, or Toms' .. the point of my reply was to highlight nto to just look into the obvious(even tho you did find a bent rod).
    If you have a length of tubing to poke into and about the place, the other end at your ear .. at least get a general idea of where it may be coming from from.
    Arthur.

    '99 D1 300Tdi Auto
    '03 D2 Td5 Auto

  6. #6
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    check the valve springs.
    Dave

    "In a Landrover the other vehicle is your crumple zone."

    For spelling call Rogets, for mechanicing call me.

    Fozzy, 2.25D SIII Ex DCA Ute
    Tdi autoManual d1 (gave it to the Mupion)
    Archaeoptersix 1990 6x6 dual cab(This things staying)


    If you've benefited from one or more of my posts please remember, your taxes paid for my skill sets, I'm just trying to make sure you get your monies worth.
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  7. #7
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    Quote Originally Posted by Blknight.aus View Post
    check the valve springs.
    Hi Dave,
    Thanks for the suggestion and, sorry if I'm being thick but, ummm, what would I be checking for please? Actually broken springs or sagged/lost tension? And the latter would mean removing and dismantling the head to check, yes?
    Thanks again.
    Ian &
    Leo - SIII 109/GMH3.3
    Daphne I - '97 Disco 300Tdi Manual
    Daphne II - '03 Disco Td5 Auto

  8. #8
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    My 300tdi has that clatter. I spent ages trying to figure out what it was, no success.
    Then I had to replace the head gasket. Took the head to be resurfaced, and was told that someone had already taken a cut and no more could be machined off, but the head was flat anyway.
    They estimated about 0.5mm had been machined off.
    Checked the valve head stand down, and they were all close to the limit due to the head machining.
    Put it all back together and all good re gasket seal, but the clatter was still there.
    Happened to do a compression check and found that 3 cylinders were at spec., but no.2 was noticeably higher than the rest, about 30psi higher.
    So I reckon the clatter is coming from no. 2 cylinder, compression is too high.
    Hope the big end bearing survives.
    Terry
    80 109" 2.6 P ex Army GS, saved from the scrappie.
    95 300tdi 130 Single cab tray.
    2010 Guzzi 750

  9. #9
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    Quote Originally Posted by Leo109 View Post
    Hi Dave,
    Thanks for the suggestion and, sorry if I'm being thick but, ummm, what would I be checking for please? Actually broken springs or sagged/lost tension? And the latter would mean removing and dismantling the head to check, yes?
    Thanks again.
    all of the above, loose collet, something stuck in the spring,

    no, remove a glow plug wind a heap of cord down into the cylinder turn by hand towards tdc then remove the collets, cap and spring.
    Dave

    "In a Landrover the other vehicle is your crumple zone."

    For spelling call Rogets, for mechanicing call me.

    Fozzy, 2.25D SIII Ex DCA Ute
    Tdi autoManual d1 (gave it to the Mupion)
    Archaeoptersix 1990 6x6 dual cab(This things staying)


    If you've benefited from one or more of my posts please remember, your taxes paid for my skill sets, I'm just trying to make sure you get your monies worth.
    If you think you're in front on the deal, pay it forwards.

  10. #10
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    I can’t seem to listen to the sounds on my phone
    But Dave I’m assuming it doesn’t sound like a too much advance rattle ?

    Timing issue ?

    So many people “time” a tdi using a drill bit which leads to funky timing

    Steve

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