Thread: Replaced head gasket now wont start 300 TDi

Valves are open when the spring is down and compressed.

Can anyone advise 1 through 8 is it from front of motor, and do i set them one at a time.
Rgs Les

the valve train starts from the front of the engine (where the fan is) and works backwards...

the best way to do the valves is thusly

get the engine at TDC on #1 (use the timing mark on the crank) then check which set of valves are on the rock, which means that both valves are open a little bit and the opposite piston on the crank (cyl 1 or 4) will have its valves both closed. this will be apparent by both valves having some lash on the rockers. These are the valves you adjust. Turn the crank over 180 degrees and the next valves in sequence will be ready to adjust (cyl 2 or 3). keep turning the crank in 180 degree increments untill youve done all the valves.

Theres a few differing opinions on weather you should do them with the engine hot or cold.

Mine says you do the final check and adjust on a hot engine and others (rovercare for one ) thinks cold...

This is a topic thats been covered a couple of times before if you search the tech threads you should find a much more detailed effort..

But if you need more help let us know.

The power of 9...

Count from the front 1 - 8. When valve 3 is fully down, adjust valve number 6 (3+6=9). When 4 is down, adjust number 5 (4+5=9). Etc...

When you go to fire it up, just make sure you've re-connected the fuel pump solenoid.

HTH

M

Instructions from Rave


ENGINE
1 ADJUSTMENT REV: 05/99
VALVE CLEARANCES - CHECK AND ADJUST
Service repair no - 12.29.48
Adjust
CAUTION: If the crankshaft is rotated with
excessive valve clearace, it is possible
that the push rods could be dislodged
from the cam follower seating and fracture the
cam follower slide. To prevent damage, eliminate
all clearance from any loose rockers before
turning the crankshaft to adjust clearances.
1. Rotate crankshaft until No.8 valve (counting from
front of engine) is fully open.
2. Using a 0,20 mm (0.008 in) feeler gauge adjust
clearance of No.1 valve.
3. Slacken locknut and turn adjusting screw
clockwise to reduce clearance and
anti-clockwise to increase clearance. Tighten
locknut to 16 Nm.
4. Repeat operation for remaining tappets in the
following sequence:
No.3 tappet with No.6 valve fully open.
No.5 tappet with No.4 valve fully open.
No.2 tappet with No.7 valve fully open.
No.8 tappet with No.1 valve fully open.
No.6 tappet with No.3 valve fully open.
No.4 tappet with No.5 valve fully open.
No.7 tappet with No.2 valve fully open.
5. On completion, recheck clearances and adjust
as necessary.

Hi all, still having some problems understanding how the firing order works.
Is there a mark on a pully somewhere that indicates when a valve is open or is it by sight. What am i looking to achieve to get it to start.
rgs Les

there's a 5mm slot in the flywheel that indicates No. 1 cyl, TDC (top dead centre) Look up though the bell housing to sight it. Be careful, there are actually two slots in the flywheel, the correct one is exactly 5mm wide. I have a 1/4 BSP nipple that I've tapped to 6mm internally, and I've machined a 6mm bolt to 5mm on the end to lock the flywheel there.

TDC is when the pump has sent it's shot of fuel to the injector, which ignites when it hits the compressed, hot air in the chamber.
At this point No. 1 cyl valves are closed. Both rockers to valves will have play (0.008'') and you should be able to slide a pin (IIRC it's something like 9.5mm) into the relevant slot/hole through the pump pulley in the timing case cover.
If you have done all this and you have fuel at the injector it will fire.

BTW, I've always adjusted 4cyl valves the way Dave describes. (used to do it a lot on certain race engines).
Just seems easier/more intuitive to me.

is it possible that the cam is 180 degrees off from the injector pump?? ie when #1 is on compression # 4 is getting the fuel?? I have never done a TDI but there are engines out there were this is possible