2.1DJ starting/running problems

[Boris89]

Thanks for the info. I re-checked the clearances and pushrods and they are all seated in the lifters. I reset the gaps but am still getting the rocker binding on the valve cap even with the adjuster backed off. Its like the lifter is too pumped up or something. I might try replacing the lifter on this valve and see if there is any difference. Leak down test seem like it might be conclusive so will ask around to find a garage to do it.

[mm289]

Let us know how you get on. When you say the rocker is binding with the adjuster fully backed of I am interpreting that as the pushrod is solid between the lifter and the rocker. is that correct?

If so it really sounds like the pushrod isnt seating in the bowl on the top of the lifter, or something is stopping the lifter from re-seating. IIRC the hydraulic lift when the lifter is pumped up isnt that great (see the link to the US site on lifters in the wiki - really useful) so for it to make the pushrod solid even when the adjuster is backed right of seems wierd.

Cheers,

MM

[Boris89]

Thats right the push rod is solid between the lifter and the rocker arm. As far as I can see the rod is sitting correctly and I have loosened the rocker assembly to get some clearance to jiggle the rod around but still cant get any additional clearance. It is wierd and from reading the US site it would appear that the lifter is pumped up with air and so not leaving any clerance for th valve. I think I will pull the rocker assembly right off and withdraw the rods to get a better look at the lifter ends.

Ta

Rob

[mm289]

Sounds like a plan

Interested to hear what you find.

MM

[Boris89]

Hello

It's been sometime since my last post so I hope someone is still watching this string.

I finally got the engine out and have now removed both the heads. As I suspected the cylinder with no compression has a cracked exhaust valve and the valve has impacted into the head almost 5mm!! No wonder I coudnt get any clearance on the rocker adjuster. The other headlooks ok although the exhaust valve has impacted slightly. Is this usual with these engines?

Fortunately the cylinders and pistons look good, very little carbon which makes me think that the engine was rebuilt not long ago.

Does anybody have a servicable LH head floating around?

Rob

[mm289]

Hi mate,

glad to hear you are making progress?

Exhaust valves will usually go first due to the adverse operating conditions (high temp etc) compared to inlet. There are also a number of posts around on AMC (Spanish aftermarket heads having weak exhaust valves - the reputable US builders replace these as a matter of course).

My first engine had small nicks in the piston crowns which looked like there had been minimal impact at some point, some pics are up on my 2.1 DJ rebuild post.

My main concern would be for you con-rods. These are known week links on these engines and if a valve has hit the piston that hard I would be worried what damage it had done to the rods. As a minimum I would be looking at replacing all exhaust valves on both heads and inspecting/measuring/replacing valve guides as required, but I would have a naggiing concern about those rods as well.

HTH

MM

[kevtherev]

Fortunately the cylinders and pistons look good, very little carbon which makes me think that the engine was rebuilt not long ago.

That's normal on an injected engine, coked engines are a thing of the past.

[kevtherev]

Hi mate,

I would be worried what damage it had done to the rods. As a minimum I would be looking at replacing all exhaust valves on both heads and inspecting/measuring/replacing valve guides as required, but I would have a naggiing concern about those rods as well.

HTH

MM

It's easy spending other peoples money
But if the piston heads are not damaged then non of that is necessary.

[mm289]

not trying to spend anyone else's money, easy or not Kev,

Just refering to Boris's post I read it as the valve had hit the piston, which is why I mentioned the con rods, on re-reading he says the valve had impacted into the head by 5mm so I stand corrected .

Having said which, most engine builders still maintain the rods are a weak link in the engine.

[Boris89]

Ok, thanks for that, I have never meddled with fuel injected engines before, just old minis in my youth. So I take it I cant get the valve seats replaced on these engines? If not seems like at least one head is junk the other possibly on its way out so im in the market for heads ........ouch!

ta

Rob

[kevtherev]

So I take it I cant get the valve seats replaced on these engines?

I don't see that posted from anyone.
head refurbs are what you pay for, valve seats are just another option