2007 MK7 2.2 RWD engine knocking

[Gfx158d]

HI,

My 2007 MK7 2.2 RWD (105k miles) suddenly developed an engine knock while driving this weekend, The van drove about 40miles fine, Parked up for about 7 hours and then as it left the carpark it start suddenly started knocking. Managed to make it home, Van drove like normal just knocking, the knocking stopped itself on 2 occasions before coming back.

Van Knocks at Idle and increases with revs, using the clutch etc makes no difference, DMF and clutch where replaced 5k ago (10 months)

I changed the Engine oil and filter as this was due (I do it every 10k), It didnt make any difference (didnt think it would but worth a shot.

I started investigating by checking the codes, no codes logged.

I then disconnected the Injectors one at a time, all equal changes of engine note, then I tried cracking the fuel line to each Injector, same result, all have the same effect on the engine.

I stripped the rocker cover off to find one of the Exhuast Value Followers on cyclinder 4 (gearbox end) had fall off the Camshaft and Valve. (moved to the side of the Cam Lobe)

I removed the Follower Carrier and inspected the Camshafts and Value all looks ok, value hieghts the same, springs look and feel ok, Camshaft has minor marks that cleaned up with a fine scoch pad. Checked lobes all appear ok, Manaully turned engine over and checked Valves moved together the same.

I inspected the Follower carrier, all appreared ok, bridges have no cracks ect, I stripped the Hydraulic Tappets out of the Carrier, cleaned them out, primmed them in engine oil and rebuilt the carrier. The only thing I noted was lots of carbon on the carrier, this is probably due to 3 out of 4 Injectors blowing. All the Tappets moved with slight resistance when refitted.

I rebuilt the engine with new seals, bolts etc.

On start up the engine sounded the same as before, I left it running for aprox 30mins hopeing it just needed to warm up and fill the tappets ect, no luck.

I restripped the engine exspecting to find a follower adrift again but all were in place. I did note that some of the Tappets now appeared to have less movement than others (when not pushing the values)

My Local Ford contact is recommending I replace the complete the Follower Carrier assembly as this is a known issue and the follower having come off orignally points to this.

Any advice of anything else that could cause this issue?

Many thanks

[tranmx2]

2021 transit.
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