Chipped Lifter cup

[Glen B]

Hi Guys,

Any one had this happen, Ideas why? Just got the diesel in from england this morning and during the tear down came across this.
It's in a 1998 300TDI.

This first one is of the 3rd from the front of the block.
http://photos-a.ak.fbcdn.net/hphotos-ak ... 9759_n.jpg

4th from front
http://photos-g.ak.fbcdn.net/hphotos-ak ... 6093_n.jpg

and 5th
http://photos-e.ak.fbcdn.net/hphotos-ak ... 4777_n.jpg

The rest look as good as 4 & 5. So I may leave them and just get one replacement, or ask the supplier to send 8 new rods and lifter cups.

Glen

[John]

Is the pushrod bent?

[Glen B]

Hi John,

The #3 push rod seems fine. I got to pulling the head appart tonight and all the rods set out side by side and there's no telling them appart. Save for the labels. And 2 little scratches about two thirds of the way down from the top on this #3 rod. Not dents just nicks.

I'll go fishing around the block tomorrow and see if I can find that bit of brass thats missing. Wasn't in the oil pan.

Sent pics to the supplier and he didn't seem to upset and is forwarding a new cup.

Glen

[Doc Tari]

Glen,
Were all the caps on the tips of the valve stems? When I bought my 300, I found a few of them had dropped into the oil pan and caused very large valve clearance. The result was that the push rod jumped around a lot and a groove was worn into the tip of the rocker arm.

Pete

[Glen B]

Hi Pete,

all the caps are there. One looked strange in that it had a bit of rust on it and the corresponding rocker, as if it hadn't seen any action in a while. All the others were oiled and polished from normal service. This tarnished cap was the #1 valve from the front. It wiped off clean but dull and doesn't look pitted, another strange find. Going to be very interested to to see the mains and con rod bearings when it all comes apart. Just got to get past that big crank nut first.

Going to be another day or so before I get back in there, what with the new shocks arriving today and the monthly meeting out at Ricky's tonight.

Glen

[John]

One scenario could be that somebody has been in there before and when they bolted down the rocker shaft assembly the push rod was not seated correctly in the cup thus breaking causing the damage that you now see.

[Glen B]

I think you are on the right track there.

There's a new head gasket, well it looks too new to be a '97 original gasket, water pump and fuel lifter as well. So some one has been in there since it was first put together at the factory. Within the last year or so looking at the lack of corrosion on the pumps.

Then they must have set the gap all wrong to take all the lift action off of that first valve and let it gum up like that.

Glen

[tony]

Hi, I've had this happen to me back 15 years ago doing a head gasket in my 2.25 diesel. I did not get the push rod centered properly but off to one side and it broke the brass follower exactly as pictured when i started the truck. Needless to say I now check and recheck before starting an engine.