300Tdi Timing belt failure and repair.. - Defender Source
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Old October 4th, 2010, 02:52 PM
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300Tdi Timing belt failure and repair..

Ok... While on the way to MAR, my timing belt let loose and stranded me. Was cruising along at 70 when all hell broke loose. Pushed in the clutch and coasted to the shoulder on I-78. I was lucky to only be 30 miles from home. Prior to this happening, I did notice the engine was smoking a little at idle but thought nothing of it since it only has 11k on the original crate motor.. Well I guess my belt was for some odd reason slowly giving way to the rover gods.

Got my valve cover off today. I have 5 bent push rods only one was bent bad. the others were barely noticeable. I will dive into the front cover next.

Questions:

Should I replace all the push rods just in case?

Do I have to remove the Rad to do the belt?

Should I remove the head to check anything?

I was going to order a timing belt kit from RDS comes with the belt, gasket, pulley and idler. What else is needed?

I still cant believe this thing broke at 11k... IT was running like a raped ape prior to this...WTF.
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  #2  
Old October 4th, 2010, 03:22 PM
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I just had to replace my turbo with 50k on it. I'll bet your whole rebuild will still be cheaper than my turbo replacement (3 bolts, an exhaust clamp and an intercooler cleaning, plus turbo=$2k). I was about 3 hours short of the go/no go decision to attend MAR. got the 110 back on Wed afternoon just in time to commit.

I know what a turbo failure sounds/feels like now. together with a timing belt failure and lift pump failure, we have all the unexpected failures a diesel can really have.

I'll still take it over ignition system failures... man I don't miss those gremlins.
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Old October 4th, 2010, 03:56 PM
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I'm not sure about the pushrods, I'd probably try to replace them personally.

When Dave and I did the timing on my 90, we didn't pull the radiator/grill to remove, but finally caved and did to put it back in. We both agreed we should've just pulled it from the first place. Not terribly hard and the clearance difference is incredible.

The kit i got from Eric @ AB was the belt, tensioner, idler and gasket but while it was open we also replaced the crank oil seal inside the timing case upon finding a small leak (that was ordered from RDS).

here's a thread Dave started on it -> http://www.defendersource.com/forum/...ad.php?t=27483

good luck!
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Old October 4th, 2010, 04:59 PM
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Replace all the push rods and check the rockers to see if they are bent. Then make sure your Belt configuration is the latest and greatest.
I do my timing all the time with the Rad in place.
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Old October 4th, 2010, 05:18 PM
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Quote:
Originally Posted by revor View Post
Replace all the push rods and check the rockers to see if they are bent. Then make sure your Belt configuration is the latest and greatest.
I do my timing all the time with the Rad in place.
and keep your fingers crossed. Another thing to do is see if valve clearances have changed. bent valves don't seat all the way and clearanes will be great.
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Old October 4th, 2010, 05:22 PM
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Good point Doug, It's hard to tell without pulling the head or putting air into the cylinder for a leak down test.. I pulled the head, just to see. Also the valves, even in good condition do not lie in the same plane across the top of the engine so if a few valve shafts stick up a little higher than the others don't worry. Just make a tool and do the leakdown test.
Don't ask me how I know...........
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Old October 4th, 2010, 10:12 PM
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I hope to have some time to get the front cover off the motor later this week. I will then take some pictures.. Anyone have the timing kit I can borrow and the lower pulley puller??

I figure I will start with the belt and get that completed first before worrying about the head. Is that a good Idea?
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Old October 5th, 2010, 07:52 AM
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Quote:
Originally Posted by TDI Guy View Post
Anyone have the timing kit I can borrow and the lower pulley puller??
If no one closer chimes in I'll send mine off to you.
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Old October 5th, 2010, 09:23 PM
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that would be great Rod. Shoot me a PM when you can. I am going to try to get the front cover off with in the next week.
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Old October 6th, 2010, 04:29 PM
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Keith or anyone, does anyone have a leak down tester I can borrow for a day? I can send it right back... I would like to check it before pulling the head. everything looks ok. Valves are sitting all flat. I only have 1 really bent push rod and 4 others that are barely noticable. I will be replacing all of them for shits and giggles though.
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Old October 6th, 2010, 04:41 PM
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I'd love to share but I transformed mine into a TD5 version. It's pretty easy to make using an old cored glow plug a good piece of hose, a cheap 500PSI gauge, a T fitting and a valve to let the air out.
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Old October 6th, 2010, 09:06 PM
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Thanks Keith.. does anyone have an old glow plug? If you can Keith, shoot a pic of yours to me.
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Old October 12th, 2010, 04:12 PM
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Got the puller and timing kit from Rod today. Pulled the front cover and the damn belt was perfect.... WTF..
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Old October 12th, 2010, 04:15 PM
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is there still a woodruf key in the gear?

Maybe try turning it by hand to see whats moving...
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Old October 12th, 2010, 04:45 PM
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Was the tension still good, skipped a few teeth somehow?
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Old October 12th, 2010, 07:51 PM
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Quote:
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Was the tension still good, skipped a few teeth somehow?
Timing is spot on as per the timing tools. The head will be coming of next to see WTF is going on..
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Old October 12th, 2010, 09:05 PM
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maybe a sunk valve seat?
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  #18  
Old October 12th, 2010, 09:25 PM
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Pull the engine out.

You need to go over everything on it. You have had to many problems with it. Will be easier to get an eye on any potential problems this way.
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Old October 12th, 2010, 10:07 PM
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Quote:
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Pull the engine out.

You need to go over everything on it. You have had to many problems with it. Will be easier to get an eye on any potential problems this way.
He is pretty close here. I would take it all the way down to the block in or out, As Doug mentioned there is no clearance on diesels like on petrol. You will kick your own ass if you spend all that time and money and don't do it all the way. If you bent push rods going 70 you likely have far deeper hidden issues. How do I know? I did it under 25 and had to replace a ton of stuff. I took it to the block and built it back up.

We always pull the radiator, it doesn't take long, it is much easier to work, and if it is used likely it is junk as well and should be replaced.
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Old October 13th, 2010, 06:29 AM
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I now do a compression test before I take an engine out or apart - just a good piece of info to have on hand.
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