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Thread: L322 M62 Vogue: Engine stuck after timing chain and guides replacement.

  1. #1
    Join Date
    May 2018
    Location
    Midland, WA
    Posts
    7

    L322 M62 Vogue: Engine stuck after timing chain and guides replacement.

    After 180.000 kilometres on the clock, the timing chain guides disintegrated and ended up in the sump. I didn't know then that this apparently is normal for this engine. Since I believe that I have better than average mechanical skills, I decided to tackle the repair myself. I ordered all the special tools from "German Auto Solutions" in the US, to lock the camshafts and crankshaft in position. I overhauled the Vanos Units and put new seals in. Replaced the chains and guides and everything looks good, so I'm ready to put it all back together.

    Just to make sure all is well, you need to turn the engine over by hand and inspect that everything is moving as it should. This is where I start running into problems. I could turn the crankshaft clockwise by hand for one and a half turn (360 + 180 = 540 degrees) before it came to a stop. I didn't force it and decided to turn it back (anti-clockwise). This time I could only rotate the crankshaft by half a turn (180 degrees) before it came to a stop. I did not force this either and turned the crankshaft clockwise again and guess what ??? This time I could only turn it for a quarter turn (90 degrees).

    Now I can only rotate the crankshaft by 90 degrees in either direction before it comes to a stop.

    My first thoughts were that I must have incorrectly locked the camshafts and open valves must be interfering with the top position of the pistons. After inspecting this over ... and over again, I am sure that I have done this absolutely correct. I even bought an endoscope, which I could lower into the combustion chambers through the spark-plug holes, just to inspect the opening of the valves, but I cannot see any anomalies.

    I disconnected the long timing chain from the camshafts and turned the crankshaft in such a position that NON of the 8 pistons are in TDC (Top Dead Centre). Now I can freely turn all the camshafts and all the valves open and shut happily.

    However .... the crankshaft still refuses to turn more than a quarter turn (90 degrees) in either direction. I made absolutely sure that non of the pistons can touch any open valves.

    I am puzzled of where to look now ??? Could somehow the gearbox or drive train be locked into the crankshaft ??? The gearshift lever is still in "P" and I am unable to shift this at the moment. I could turn the crankshaft before I disassembled the engine.
    Can anyone offer suggestions of how to proceed?

    Thank you.

  2. #2
    Join Date
    Jan 1970
    Location
    Avoca Beach
    Posts
    11,268
    The gearshift lever is still in "P" and I am unable to shift this at the moment. I could turn the crankshaft before I disassembled the engine.
    Can anyone offer suggestions of how to proceed?
    I n"P" there is a pawl which drops into a hole in the input shaft and locks the transmission and engine.
    The pawl may not have dropped in before you initially turned the engine.

    You should be able to move out of "P" if there is no pressure on the transmission ie you are between the two stops . Or perhaps jack up one wheel as the transmission may have a bit of windup which is preventing it from disengaging.
    Regards Philip A

  3. #3
    Join Date
    May 2018
    Location
    Midland, WA
    Posts
    7
    Thank you. Will try this over the weekend

  4. #4
    Join Date
    Jan 1970
    Location
    St Helena,Melbourne
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    12,078
    Park doesn't lock the crank otherwise you would kill box and motor shifting with engine running.
    MY08 TDV6 SE D3- permagrin ooh yeah !
    98 TDI AUTO SE DISCO - gone and will be missed.
    2003 Dingo offroad camper trailer
    1998 Triumph Daytona T595
    1974 VW Kombi bus
    1958 Holden FC special sedan

  5. #5
    Join Date
    Mar 2007
    Location
    Warwick Qld
    Posts
    1,677
    Could be a sump off job. Sounds like something is fouling the crankshaft. Did you get all the pieces out?
    When you say the chain guides disintegrated, did the engine stop? As in, suddenly?
    Could be something like a piece of piston catching somewhere.
    -----
    You have the right to remain silent. Anything you say will be misquoted, then used against you.
    -----

    1999 Disco TD5 ("Bluey")
    1996 Disco 300 TDi ("Slo-Mo")
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    -----

  6. #6
    Join Date
    Jan 1970
    Location
    In my D2a Ripping It Up
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    9,844
    Could simply be a part of the guild or chain that has dropped down the T/cover and jamming against the sprocket if your lucky
    If not sump off
    cheers chris


    My Toy 04 D2a Td5 Manual With Lots of Goodie Goodness
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  7. #7
    Join Date
    Jan 1970
    Location
    Avoca Beach
    Posts
    11,268
    The other posters are correct and I am wrong.
    The pawl should not lock the motor, only the transmission.
    Seniors moment
    Regards Philip A

  8. #8
    Join Date
    Jan 1970
    Location
    St Helena,Melbourne
    Posts
    12,078
    Is the chain routed correctly and tensioned ?
    MY08 TDV6 SE D3- permagrin ooh yeah !
    98 TDI AUTO SE DISCO - gone and will be missed.
    2003 Dingo offroad camper trailer
    1998 Triumph Daytona T595
    1974 VW Kombi bus
    1958 Holden FC special sedan

  9. #9
    Join Date
    May 2018
    Location
    Midland, WA
    Posts
    7
    Just to reply to some of the suggestions above: The sump is still off and everything is clean. The engine was still running when I started the job, but when the chain guides start to disintegrate you'll find bits of plastic in the sump. I'm sure that nothing is obstructing the engine internally. I did not leave any tools behind or drop bolts and nuts into the engine. The front of the engine is still open and I have removed the long timing-chain for the moment. Also the rocker covers are still off and the 4 camshafts are visible. I am able to rotate the camshafts without problems.

    I am still unable to shift the gear leaver out of "P" and perhaps the transmission and drive train are engaged somehow.

  10. #10
    Join Date
    Dec 2017
    Location
    wandin nth vic
    Posts
    101
    Just a thought. Can you get to drive plate bolts to disconnect the torque converter to eliminate transmission?

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