Tappet noise!

[KittyCamper84]

Hi, we have just rebuilt the engine in our camper (1.9DG) due to the head gaskets failing. Since it has been back running there has been a loud clacking noise which i'm sure is a tappet, as when it is running slow it drops to 3 cylinders due to the poor valve timing. Annoyingly, the tappets were the only bit i didn't touch ( ) and i sort of hoped it would get better after a few miles, but we have covered 450 now and its still not right. I have tried readjusting the tappets but it made no difference. How can i find out which tappet is at fault?

Please help as we are going away on 3rd June and i'd like to know its ok before we go!!!!!

Thanks

[kevtherev]

How can i find out which tappet is at fault?

At TDC on the firing stroke (both valves shut) push the rocker arm that rest on the pushrod, if it is spongy then thats the fella.

read this as there is a ton of infomation to help

http://www.ratwell.com/technical/HydraulicLifters.html" onclick="window.open(this.href);return false;

[KittyCamper84]

A further update! We have now covered a fair few miles as the van is used as our daily transport, and the tappet noise is still there. I have read all the info on the link (thanks Kevthrev) and carried out the checks suggested but the are all hard, no sponginess at all?!

I took a video of it to show on here to hopefully confirm it is a tappet:

http://s219.photobucket.com/albums/cc12 ... G_0219.mp4" onclick="window.open(this.href);return false;

I am now at a loss as to what to do, can't really afford to change them all in hope of fixing it, but we are going away to north Devon in 10days time and i'm a bit worried about damaging something on a long prolonged journey.

Is anyone near me an 'expert' who would be able to come have a look and help me out?

Thanks in advance!

[kevtherev]

It would suggest that the tappet is damaged if ajustment and all else has failed.
Not a difficult job and is possible without removing the head.

[Jeff J]

Not sure I can help as I am just a newbie, but I have had exactly the same problem on mine, but after it has been stood for 5 years. The longer it runs the less noise it makes & but as it is not yet on the road yet I have not been able to give it a long run like you, to see if it goes completely. I managed to confirm it was tappet noise by using a long screwdriver with the handle held to my ear & the tip against the engine. Although no one was able to tell me further damage would or would not be caused by running it in this condition, logically I would think that it can only damage the end of the push rod as it appears to me, as an amateur, that is what it is slapping against. So if you have to remove/replace the tappet you will be able to check it at the same time.

[kevtherev]

The abnormal wear occurs at the valve head
the noise is the rocker arm battering it flat.
Once the tappet is pumped up any differences are taken up
so no harm done

[KittyCamper84]

so is there a way i can easily tell which one it is as i cant aford to do them all! i imagine they all drained down during the rebuild but one has got stuck. What do you think to special lifter oil?

[Tug]

strange this.....I carried out a top end rebuild on my Aircooled 2.0 700 miles ago....and I have one tappet that rattles. I have just drove 500 miles up too scotland and its still rattles. I am begining to think its a lazy follower as it only does it above 3000 rpm and if i really give it some beans on hills etc it goes away....I will tear it down when I get back. It drives me nuts as it sounds so sweet when its cold. All my followers were replaced by the way..
Glenn