2.1DJ - clacking sound (tappets?) after head refit. Video link included

[ManicGTI]

So, up and running again after my last thread, but have this pretty loud clacking/tapping sound, Youtube video below:
https://youtu.be/hV7QcFBxneI

Honestly I've forgotten what these engines sound like. I'm sure it wasn't this loud before. Feels like it's coming from the nearside of engine but tricky to really tell.

Ran it until warm then dumped flushing oil, refilled with new decent stuff and new filter before driving.

This was taken before first run, but I've driven to work and back today (about 30-40 miles) and sound hasn't abated at all.

Struggling to tell if this is a 'panic and don't go anywhere', or 'go over timing/clearances and push through it' moment.

Apologies for the multiple posts, I can do in one thread if better for forum?

Thanks,

David

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[maxstu]

Sounds like typical hydraulic tappet bleed down to me. Twenty minutes normal driving should sort it out.

[ManicGTI]

Sounds like typical hydraulic tappet bleed down to me. Twenty minutes normal driving should sort it out.

Thanks, I did drive it for about 90mins today, London driving so a bit stop start and max 40-50mph. I'll try and give it another run tomorrow and see if it makes a difference.

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[maxstu]

Any improvement to report?

[ManicGTI]

Sadly I didn't get a chance to give it another drive. I had to get a load of work done before holiday so decided to take the less risky route (3 young kids...) and come in the Mk5 Golf.

Possibly not relevant but thought I'd 'start again' on set up to make sure I'm not missing something obvious. Timing is good @10deg (super), good compression and have spark at all 4 cylinders. Will redo rockers when I get back. Check injectors etc.

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[Stesaw]

Im interested to see your findings on this. I get what sounds like tappet rattle on my 2.1 when warm. Lifters seem solid though. Maybe i might swap from 15w40 to 20w50 oil and see if that makes a difference..

[R0B]

My old engine suffered from tappet drain down if the van was left standing for a week or so. This stuff worked well. (Other brands are available)

[ManicGTI]

For ref I'm using Morris 15w40 Mineral Oil at the mo. Def happy to try some 20w50 to see if it makes a difference.

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[maxstu]

I use 15w50 mineral oil.

[Stesaw]

For ref I'm using Morris 15w40 Mineral Oil at the mo. Def happy to try some 20w50 to see if it makes a difference.

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Yeah im using that exact oil as well.
I think next oil change ill go for a 20w50 maybe get some of that liquid moly oil.

[ManicGTI]

Ok, Halfords 20w50 going in tomorrow and we'll see how it goes.

As it happens it looks like i'll be pulling it for an EJ25 in the next few weeks (classified ad for the DJ incoming), but if I can sort this then all the better for any purchaser.

[Smiffo]

I might be interested in a Dj when the time comes.


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[Stesaw]

I might be interested in a Dj when the time comes.


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If you've got money to burn fit a 1.8t. That was going to be my other choice but I wanted to build an engine

[Smiffo]

I might be interested in a Dj when the time comes.


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If you've got money to burn fit a 1.8t. That was going to be my other choice but I wanted to build an engine

I have a soft spot for the WBX.
it doesn't make sense, but it is a driver to maintain an original engine for as long as viable.

( Until they make rules around emissions that the vans can't meet. )
 

[Stesaw]

Thats fair. I guess with people like marco making efi kits for them and turbo kits make the waterboxers much better than using old efi or carb for sure... just the price tag is what makes me think just put a modern lump in.