UPDATE: Further issues after replacing broken rocker arms and bent pushrods

[Craig Almaguer]

(BACK STORY)….
After replacing a new timing belt kit,….after three hours of driving, the relay pulley was set, proud, by the tension pulley bracket (relay pulley did not lineup with the hole on the tension arm). Huge mistake. This caused the new belt to slip towards the rear of the pulley assembly and break and shred. new belt and crank pulley ordered and in hand.

(UPDATE AS OF 12/12)….
Replaced the pushrods and broken rocker arms, and adjusted the valves. Set new timing belt, tensioner, pulley and relay pulley and new crank pulley at the bottom. TDC set.

Truck starts right up and runs “well”….Here are the new problems:

1. Increased black smoke at tailpipe at start up and more black smoke (more than usual) while reving the motor. After new injection pump and timing belt replaced (above) I noticed considerably LESS black smoke at start and acceleration through the gears.
2). Oil leak (a steady slow drip coming from behind crank pulley. Could this be from blowing the timing belt? New seal needed? Other seals or o rings needed?
3). I also notice some fuel around nut flange holder of injector, one, and a bit at the back, injector four. Could it also be from the pressure received from blowing the timing belt? New copper washers at bottom of injector needed? Or?

I did not go further and remove head and I did not do much valve inspection beyond a visual up top during rocker arm and push rod replacement.

Thanks in advance!

Craig
Marlin the Rover
Defender 110 300 TDi

 

[Mirrajumper]

Not to add more work to your list….. but…. a new head gasket is within reach since you are already doing the other repairs. How many miles on the current one?

 

[Frenglish]

Hi, firstly you can do this, and you will feel proud and accomplished for having done it after your done. Nothing on this truck is that complicated and in theory can be done in a farmers field or on the trail. But.. we need to look at some things given the damage done.
And not to scare you more, but we need to look at the pistons and valves too. The rocker arms and push rods didn't break on their own, they were forced into this situation from the valves contacting the pistons and we should check for any damage or bent valves. This would certainly make Mirra's suggestion for a head gasket a worthwile endeavor as well.

I would be happy to share with you a .PDF repair manual, but I can also point you in the direction of the land rover toolbox videos on Youtube.

Love these vids

I have completey rebuilt my 200tdi and I can tell you this job is doable and not as scary as it looks. Let us all know if you need more help along the way.

 

[Craig Almaguer]

Hi, firstly you can do this, and you will feel proud and accomplished for having done it after your done. Nothing on this truck is that complicated and in theory can be done in a farmers field or on the trail. But.. we need to look at some things given the damage done.
And not to scare you more, but we need to look at the pistons and valves too. The rocker arms and push rods didn't break on their own, they were forced into this situation from the valves contacting the pistons and we should check for any damage or bent valves. This would certainly make Mirra's suggestion for a head gasket a worthwile endeavor as well.

I would be happy to share with you a .PDF repair manual, but I can also point you in the direction of the land rover toolbox videos on Youtube.

Love these vids

I have completey rebuilt my 200tdi and I can tell you this job is doable and not as scary as it looks. Let us all know if you need more help along the way.

Thank you for the words of encouragement. I do have the PDF shop manual.

 

[Craig Almaguer]

Not to add more work to your list….. but…. a new head gasket is within reach since you are already doing the other repairs. How many miles on the current one?

Thanks Mirra! Vehicle has 130,000 miles.

 

[Craig Almaguer]

Hi, firstly you can do this, and you will feel proud and accomplished for having done it after your done. Nothing on this truck is that complicated and in theory can be done in a farmers field or on the trail. But.. we need to look at some things given the damage done.
And not to scare you more, but we need to look at the pistons and valves too. The rocker arms and push rods didn't break on their own, they were forced into this situation from the valves contacting the pistons and we should check for any damage or bent valves. This would certainly make Mirra's suggestion for a head gasket a worthwile endeavor as well.

I would be happy to share with you a .PDF repair manual, but I can also point you in the direction of the land rover toolbox videos on Youtube.

Love these vids

I have completey rebuilt my 200tdi and I can tell you this job is doable and not as scary as it looks. Let us all know if you need more help along the way.

Thanks again! Any additional thoughts to my new issues?

 

[Frenglish]

Thanks again! Any additional thoughts to my new issues?

I think I would warn against "ship fitters disease." (Read desc here ) But overall I think an inspection of the valves and a new head gasket with everything else should get you where you need to go. I do not necessarily suggest doing the valve guides unless they are damaged, but maybe the valve stem seals would be worth it because if you are that far in there it would be easy.

the pushrods run on little brass bushings that can also be easily inspected when the head is off. I unless they are scored and missing parts or cracked I wouldn't unnecessarily replace them. I would check other parts for cracks or chips just to make sure.

Plenty of cheap tools available to get this job done like valve spring compressors. Those videos are descriptive enough to walk you through all of it. head bolts are reusable so thats a plus.