TD5 Camshaft damage - any input

Ok, lets update this.

The head was built, with almost all new parts, refitted, still smoked.

Compression test revealed very low results. in the range of 150-165psi.

Not good so I have pulled it out - few pics for anyone keen to see how it progresses.. I will do a proper thread on how to rebuild it when I find out how to do it!

Removing the engine. I removed the head seperately as I managed to round one of the belhousing bolts

https://www.aulro.com/afvb/images/im...11/12/1261.jpg

Clutch and flywheel removed. Some evidence of heat/slipping on it, and there is a reasonable amount of play on the flywheel, more worryingly play like a wheel bearing as opposed to rotational freedom.

A solid flywheel from Rakeway will go back in the same as my 90.

https://www.aulro.com/afvb/images/im...011/09/948.jpg

Removing the ancillaries:

https://www.aulro.com/afvb/images/im...011/09/949.jpg

https://www.aulro.com/afvb/images/im...011/09/950.jpg

Remove oil pump:

https://www.aulro.com/afvb/images/im...011/09/951.jpg

One bolt was missing and is broken in the main bearing cap:

https://www.aulro.com/afvb/images/im...011/09/952.jpg

Next remove the front pulley. This is ridiculously tight. 340lb/ft I think I made a tool, then ratchet strapped the whole lot to the bench, and got someone to stand on the end of the tool while I also stood on it an undid the bolt. (thanks to the JC technical support line to check the thread direction!:)):

https://www.aulro.com/afvb/images/im...011/09/953.jpg

Crank looks good:

https://www.aulro.com/afvb/images/im...011/09/954.jpg

Main bearings all look good, but 3 of the 5 big end bearings on the rod side are through the white metal.

https://www.aulro.com/afvb/images/im...011/09/955.jpg

The bores look ok, as do the pistons, but they are obviously slightly dodgy!

Will grab some pics of those in day light tommorow

Crank looks perfect.

Hope things go well with the rebuild.

Since you originally mentioned the engine smelt a bit fuellie, perhaps the cause was related to fuel dilution in the sump. Perhaps it was leaking mostly from the injector seal near the cam lobe that was most degraded and the dilution resulted in accelerated engine wear and hence low compression overall ?

Anyway, looks like you are giving her a new life :) - best of luck!

Hi Taz,

Thanks for the reply.

The injector seals seemed to be fine. I had kept a very close eye on it over the couple of thousand k's it did prior to me puling the head, and there was no sign of diesel getting through to the sump.


Rgds
Peter.

checked the con rods yet?

cheers phil

Quote:

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Originally Posted by discowhite

checked the con rods yet?

cheers phil

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Have now Phil!:

Number One is visibly bent. Others look ok, but I am not convinced!

https://www.aulro.com/afvb/images/im...011/09/883.jpg

There is your low compression reading peter, even a fraction of a mm less piston height will be enough. Looks to me as though this engine has had a bit of a chequered life:mad:

Broken bolts, knackered cam, bent conrod, etc etc.

JC

Quote:

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Originally Posted by Psimpson7

Have now Phil!:

Number One is visibly bent. Others look ok, but I am not convinced!

https://www.aulro.com/afvb/images/im...011/09/883.jpg

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yep,,,thats bent. bet your wishing you had checked the piston protrusion now:o

cheers phil

Really interesting thread. Love to know the history of that engine. I've seen something similar before but not all that damage. Vehicle had the wrong oil in it for a while and also had diesel leaking into the sump. The diesel leakage could have been there for quite a while as it was caused by the infamous crack in number 3 injector housing. Once the crack got big enough the diesel leakage became obvious but the owner didn't pick it and merely replaced the seals. Leaked again of course. The result of this was enough camshaft wear to mean replacing it along with another head. Also had to replace a couple of the injector rocker arms.

Thanks guys.

Ok I have just put in a large order from Turner Engineering in the UK on behalf of the owner for the following:

Con Rod x5
Piston assy +.020 x5
Main Bearing set
Big End bearing set
Big End bolt set
Main bearing bolt set
Thrust shims x2
Front pulley bolt
Timing chain kit
Timing chain guide 1
Timing chain guide 2
Oil pump chain kit
Bolt oil pump gear
Oil pump bolts short x 10
Oil pump bolts long x 12
Timing cover fan bearing
TD5 Bottom end gasket set
Valve stem oil seal

Still to order once the bottom end is together:

Head Bolts x12
Head Gasket
Solid flywheel and clutch.

Block will go down to machine shop as soon as Pistons arrive. cost for the rebore and hone is around $220

Currently looking like this as of last night. Happily I managed to remove the broken bolt in the cap fairly easily

https://www.aulro.com/afvb/images/im...011/09/809.jpg

2 lots of parts have arrived from Turners in the UK.

Truly fantastic service from them every time.

https://www.aulro.com/afvb/images/im...011/09/579.jpg

Block is going for machining tommorow with the pistons.

Rgds
Pete