1980 240D om616

After weeks of mechanical restorations and buying a non running 240D I went from great power going up an on ramp on highway it sounded like major piston slap ticking all of a sudden. No smoke or power change on this event.

Got home and checked valve clearance (they where all still fine really) after it cooled down Basically no start afterwards.

I have done SO much work on this including valve clearance adjustment , all 3 fuel filters, primer, oil change , iP timing and was driving last entire week with it no problems.

I was so convinced of major piston damage / slap I pulled oil pan and ZERO evidence of a problem like this.

The only discrepancy I have found is the #4 injection pump delivery valve where hard line attaches is very dry and a very different pattern When I crank engine over unlike 1-3. The engine would only now start after the cool down with full throttle and a lot of fuel smoke.

Car was starting at 40 degrees on first rotation days ago.

Loosing courage to make this a daily driver now

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1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner

Also, bosch shop did the injector calibration/cleaning and I also reset the IP over pressure valve spring and various fuel lines also so should not be issue.

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1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner

Compression?

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1978 300D, 373,000km 617.912, 711.113 5 speed, 7.5mm superpump, HX30W turbo...many, many years in the making....
1977 280> 300D - 500,000km+ (to be sold...)
1984 240TD>300TD 121,000 miles, *gone*
1977 250 parts car
1988 Toyota Corona 2.0D *gone*
1975 FJ45>HJ45
1981 200>240D (to be sold...)
1999 Hyundai Lantra 1.6 *gone*
1980s Lansing Bagnall FOER 5.2 Forklift (the Mk2 engine hoist)
2001 Holden Rodeo 4JB1T 2WD

Start with your hunch about the injection pump. Pull the hard lines off and crank the engine over. All 4 ports should be spurting fuel in firing order. If #4 is wimpy or not spraying, you found part of your problem.

The "piston slap" noise could have been nailing or injection problems. The noise made by poorly controlled injection can be very sharp and loud with a metallic sounding noise. Literally sounding like a hammer on an anvil. Pop your injectors out and pop test them or have them tested for pop pressure and spray pattern. While they're out, check for the presence of the "ball" in the prechamber.

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Current stable:
1995 E320 149K (Nancy)
1983 500SL 120K (SLoL)

Black Sheep:
1985 524TD 167K (TotalDumpster™)

Gone but not forgotten:
1986 300SDL (RIP)
1991 350SD
1991 560SEL
1990 560SEL
1986 500SEL Euro (Rusted to nothing at 47K!)

Post a video of the sound, could be something not in the bottom end.

Well the pump output looked normal this am but I cannot get car to start at all now.

Here is video of injection output with hard lines off. Correct/normal? It IS equal from all ports this am

https://www.youtube.com/watch?v=bCzb-5nDMsM&feature=youtu.be

__________________
1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner

Ball in chamber:
I see this in all 4 chambers?

Attached Thumbnails

 

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1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner

Now as of this am after a tow start it’s like injection timing is way off again. Very odd as it was making the sound suddenly but no smoke yesterday.

Near engine bay

https://youtu.be/MRaBvW4skSM

__________________
1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner

You don't have an om617 engine (5 cylinder)


you have an OM616 (2.4 4 banger)

Thanks for probably flagging my YouTube video which was unlisted and by someone on here.

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1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner

Why the F*** would I want to flag you video?

have some proof before you accuse someone of something.

wtf

So I could correct the description on titles on YouTube and also here.

__________________
1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner

knowing the correct engine number will help you when looking up service information and buying parts or asking for info on forums.

After suspecting the injection pump timing off for some reason I sure enough checked it and it was over six teeth off from where I had previously set it and the engine had been running perfectly… I reset the injection pump and got it back to where it is running on its own without smoke in normal power starting on its own but it is quite clear to me but the timing chain allowed to skip and significant damage i.e. piston slap apparently.

Here is a video:

https://youtu.be/mgBdMEIXpJ4

__________________
1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner

https://youtu.be/mgBdMEIXpJ4

__________________
1980 240D Manual

2013 Jetta TDI

AP Mechanic, Misc. Diesel equipment owner