Mk7 2.2 85ps ticking/knocking

[tjm07]

Appreciate your time and input, I will check when the new head gasket arrives (tomorrow hopefully) but I have ordered a 3 notch so should be the thickest at 1.2mm. Here's hoping it's just the cam timing. I intend on marking when number 4 is at tdc and seeing what the valve is doing at that time. Will keep posting!!

[bambi mk 1]

Thoughts and theories on why the brand new piston has a valve mark on it? Timing still looks good and was timed using pins?

Have you fitted a new chain Tensioner looks near end of travel

[amlav]

You probably know that but just in case .... With piston at TDC you should feel a small ammount of free and equal movement on all rockers on that cylinder .

Thoughts and theories on why the brand new piston has a valve mark on it? Timing still looks good and was timed using pins?

Have you fitted a new chain Tensioner looks near end of travel

+1 on tensioner travel

[tjm07]

All comments and suggestions taken on board and will feedback once i have progressed. Thanks again

[paul2012]

I've just looked at OP pics of his engine.

1st Clearly shows in this pic.A all 4 pistons have hit exhaust valves

IMG_1026.JPG

Timing chain had badly stretch. This will lead to incorrect valve timing.

IMG_1077.JPG

Solution. Replace all 4 pistons (hone cylinders). Check con rods for damage & If necessary replace.
Always fit new big end shells when replacing pistons etc.

Fit new timing chain kit

[tjm07]

Hi Paul, have followed a few of your builds and am really impressed with what you do, so with that in mind I take you're advice on board. New big end shells installed engine built back up ( although haven't replaced pistons, not because I think you're wrong, it's purely due to cost) did inspect bores 1-3 and the original hone marks are still visible, new head gasket, now just awaiting delivery of timing chain kit. Have also marked when 1&4 are at tdc, so once timed up will be able to be certain valves are closed before piston gets there. Thanks very much for all the advice, will update when more progress is made.

[tjm07]

Any ideas fellas? No obvious wires dangling, do i need to look harder?

[motorman116]

Any ideas fellas? No obvious wires dangling, do i need to look harder?

I would say that, that's the oil pressure sensor, that goes to the oil light on the dash

[tjm07]

Still struggling, engine rebuilt and put back in, started up fine sounds really good, revved up to about 3k and then the dreaded knock returned and has remained. Immediately removed timing chain cover and rechecked timing, all pins fell in, where to go next?

[tjm07]

Does anyone know the dimension on the crank shaft locking pin? I found a dimension on this forum of 9.75mm, I have turned a pin to suit, it only fits in one slot on the reluctor ring, can anyone measure there shop bought pin to confirm size is correct. I am still hearing the noise, can't see for any reason why, really clutching at straws now, head will be coming back off imminently and measuring to see if it has been skimmed, does anyone know what it should measure? Does anyone have any other suggestions, I have no problem replacing parts I.e the head if I can prove it's at fault and will solve my problem. Before the head comes off I am measuring with dti's when cylinders are at tdc, and what the valves are doing in relation to it?

[tjm07]

Still had that niggling doubt that the knocking I was hearing was a piston hitting valves, so removed head. Pleased that there is no new evidence of a collision, but now i have to look elsewhere for the source of the knock. It seems more prominent when warm, the rocker cover is chuffing, so I suspect injector seat need recutting and new seals, could this cause a knock?

[75psT330lwb]

Did you have the injectors checked??

[tjm07]

I haven't as yet, will have to try and find someone locally, any suggestions/recommendations in east Kent? My other concern is that it is piston slap, so I shall borrow some measuring equipment from work on Monday and measure bores, number 4 obviously bring my focus as this is one I honed. Before stripping engine I was trying to identify problem an unplugged injectors 1 by 1. The noise reduced by 75% when number 4 was unplugged, does this help prove anything?

[tjm07]

So bore has been measured and is 0.08mm larger than the smallest bore of 86mm. So I have cylinder 1 at 86.01, 2 at 86, 3 at 86.02 and 4 at 86.08, I had equal compression after the first assembly, so unless anyone advises against I am going to re-assemble, and then try and move injector 4 to a different cylinder (have f-super) and see if the noise goes with it? Advice/thoughts welcomed

[tjm07]

https://www.youtube.com/watch?v=K7LvKKB3hug&sns=em. Please listen to vid and share your views on cause of noise