240 D no start
 

616 engine ran fine and started easily sitting in the bay and running on ATF/diesel in a bottle, also started fine when hooked up to fuel lines and primed, ran w/ euro manifolds (no air cleaner for euro manifolds tho).

Installed air federal (I think, ugly egr setup connecting the manifolds) manifolds, water pump, radiator, chain tensioner gasket, throttle linkages, driveshaft, exhaust yada yada yada. Hit the starter, starts right up (well, after I reconnected the ground) vague crunching noise and stops. Spins, primes OK, injectors bleed OK. No firing of any kind

Ideas? I hope that vague crunching noise was because the engine stopped suddenly and not the other way around. Looked in the oil cap didn't see chips, haven't pulled the valve cover yet.

I hope there was not debris in the new intake that has damaged your cylinders and or pistons. Does it have oil in the crankcase?

Started up then vague crunching noises - stop. Now wont start. Sure sounds like something got sucked in. I'd take the intake back off and inspect.

Hopefully no damage to internals.

when the camshaft snapps, there is a vague crunching noise...

Thats what I was thinking. Brittle failure, low energy=low noise. Spare on the other engine I guess.

<Partial potentially misinformative procedure edited out>

The shop manual or other detailed resources are a good guide for a camshaft R&R

This week has been like catching a bummer in the surf. More like a few. On the upside, I maintain a positive attitude, and very much enjoyed a new album today. Not a bad day for as car hell goes.

Mysterious destruction within. #2 exhaust follower flipped over and bent, a score where it dug into it's corresponding lobe, tower support for same a bit tweaked. Excessive clearance on #1 exhaust I think. 3 & 4 look OK.

Seems like it spun up pretty fast when it last started last, I wonder if a valve floated.

Looks like a cam R&R & valve adjust, cross fingers, try again.

Still odd, seems like it should fire on 3&4.

Related note, the round part on an IP, looks like a little air cleaner with a nipple on it. Is this the shut off valve connection?

Root cause:
When I first bought the engine back in 09, I did a leakdown test on it, noticed that some of the valves were worn out of round, and sealed better in their happy spot. I did some messing around, had the followers in & out, closed it up and left it for later. I'm sure something was left for later and not as tight as it should be. Shame on me for passing up chances to fix old mistakes.

It lives. Cam intact, internals intact. Extracted & replaced sheared woodruff key (both fragments). Replaced followers, rack & bolts for cyl's 1&2 w/ same from old engine. Mechanic friend has seen it before, said the gouge from the old follower in the cam lobe would burnish out. Set valve lash, checked it over, closed it up, crossed my fingers & cranked. Runs well, car is rolling.