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Just changed headgasket... Now broken auxiliary shaft... 

 

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 Post subject: Just changed headgasket... Now broken auxiliary shaft...
Posted: Fri Jul 20, 2007 6:54 pm 
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I'm at my goddamn wits end...

My headgasket blew a few days ago and I've just finished putting it all back together with all new gaskets and machined head.

I thought it started ok until I noticed a noise coming from the timing gear/belt drive area at the front of the engine. So I picked up the revs to see if it would go away and at 3500rpm the revs dropped and it died...

So I pulled the tappet cover off and checked everything and upon seeing that all seemed ok I put it all back together and started it again... This time it ran PERFECTLY! ... FOR 5 f**k MINUTES.

So after running like a dream, just idling, for 5mins it turns itself off. Doesn't conk out or anything rough, just calmly turns itself off... So I turn it back on and it's running rough again and the noise is back!

So, here's a summary of the probem...

- Strange noise, almost like a whine, coming from the timing gear/belt drive area at the front of the engine.
- On start up the revs jump to about 3000rpm.
- It's running rough at idling revs.

PLEASE HELP ME!!!!!! :x :x :x :x :x :x :x :x :x

Last edited by MoNGooSE on Sun Jul 22, 2007 8:00 pm, edited 1 time in total.

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Posted: Fri Jul 20, 2007 7:35 pm 
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MadMatt seems to think I over-tensioned the timing chain... Any thoughts before I pull the piece of s**t apart again tomorrow...
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Posted: Fri Jul 20, 2007 7:39 pm 
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Seems all very weird. Have to double checked that the cam timing is still set right.
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Posted: Fri Jul 20, 2007 7:39 pm 
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Yeah, I'd be checking that tensioner too. If its too tight, it will chew into the engine block, the aux shaft that is, seen it happen before.

 

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Posted: Fri Jul 20, 2007 7:40 pm 
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MoNGooSE wrote:
MadMatt seems to think I over-tensioned the timing chain...


yes that is quite possible

 

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Posted: Fri Jul 20, 2007 7:41 pm 
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Did you pull apart the tensioner??? did you replace the O'rings??? How dirty was the filter for the tensioner???

 

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Posted: Fri Jul 20, 2007 8:01 pm 
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have u checked for vacuum leaks ?
might explain the ruff idle,
don't know bout the noise
might be a bit of chain slap - depending on how much was shaved off the head, or chain is loose.
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Posted: Fri Jul 20, 2007 8:58 pm 
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4LEDboy wrote:
MoNGooSE wrote:
MadMatt seems to think I over-tensioned the timing chain...


yes that is quite possible


i fail to see how it is posible to over tension the timing chain. considering the running tension is set by oil pressure.

seting it is only a mater of locking it compressed and once installed realesing the lock with a small alen key.

 

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Posted: Sat Jul 21, 2007 1:13 am 
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tickford_6 wrote:
4LEDboy wrote:
MoNGooSE wrote:
MadMatt seems to think I over-tensioned the timing chain...


yes that is quite possible


i fail to see how it is posible to over tension the timing chain. considering the running tension is set by oil pressure.

seting it is only a mater of locking it compressed and once installed realesing the lock with a small alen key.


Except I didn't do that... I just removed the retainer and all as it was locked together tight...
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Posted: Sat Jul 21, 2007 1:16 am 
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sounds like you may have mangled the tensionor then. Given the rough idle and increased RPM, I would be looking for a vacuum leak somewhere. I have seen the MAP sensor tube fall off and do what you are experiencing.

 

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Posted: Sat Jul 21, 2007 1:18 am 
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Dad the mechanic is gonna' take a look at it tomorrow, check for vacuum leaks and timing problems.

If he can't fix it then I'll get MadMatt the wizz to have a look on Sunday.
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Posted: Sat Jul 21, 2007 9:22 am 
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isnt the tensioner self setting after u realease it when its in? id be checking around ur BBM for hoses that have come off.

 

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Posted: Sat Jul 21, 2007 4:19 pm 
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Well we reckon we've found it... And it's none of the above suggestions.

When Dad first took the tappet cover off and checked the tension of timing chain he noticed that one of the sprockets towards the bottom of the motor seemed to have a fair bit of play in it. We disregarded that and went about checking all the obvious things...

We went over the engine with a fine tooth comb and found no vacuum leaks so we set the tension on the timing chain properly and fired her up again and sure enough the noise and crappy running was back but this time a hell of a lot worse.

So Dad went back to his first inkling of the loose sprocket down below. Upon referring to the trusty old Gregory's EF Falcon Maintenance Manual we realised that the loose sproket was none other than the sprocket attached to the auxiliary shaft which controls the dizzy and oil pump!

So Dad is down at the wreckers now trying to pick up a replacement chain, shaft and sprocket so we can replace it!

We're not sure whether the bolt has broken which holds the sprocket on or what. But it would explain the crappy running, erratic missing and loud whining noise coming from the area...

Has anybody else every encountered this?

We're taking the timing cover off when he gets home and checking it out...

Last edited by MoNGooSE on Sat Jul 21, 2007 8:14 pm, edited 1 time in total.

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Posted: Sat Jul 21, 2007 8:11 pm 
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We just finished taking the timing cover off and what do you know... Dad was right...

The bolt holding the auxiliary shaft sprocket on came loose. Probably due to my chain having a little play in it and it not being lock-tighted on when it was last removed. So when I released the tensioner to remove the head it must have moved the sprocket around just enough so that when I started it up after putting everything back together it tore the locator pin out of the centre of the sprocket and in turn put the dizzy and oil pump all out of whack and caused it to run like s**t!

So now I have to replace my timing chain, auxiliary shaft, auxiliary shaft sprocket and the bolt holding it in...

Thank God my dad is my dad :D

Some pictures for your viewing pleasure...

 

 

Attachments:
File comment: The locator pin has been torn right out the centre of the sprocket...
DSCF0787.JPG
DSCF0787.JPG [ 187.46 KiB | Viewed 65 times ]
File comment: Comparison with sprocket we got from wreckers...
DSCF0786.JPG
DSCF0786.JPG [ 150.25 KiB | Viewed 68 times ]
File comment: Comparison with bolt we got from wreckers...
DSCF0785.JPG
DSCF0785.JPG [ 153.69 KiB | Viewed 52 times ]
File comment: It was ONLY JUST sitting there :-S
DSCF0780.JPG
DSCF0780.JPG [ 155.26 KiB | Viewed 62 times ]
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Posted: Sat Jul 21, 2007 9:40 pm 
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Geez..... lucky you stopped running it when you did. If that sprocket actually managed to fall off, it might have meant the end to that motor!

I wonder if I have a similar problem.... Trying to find the source of a chain like rattle in the EF.

 

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