Delica JB500 Camper

Growlerbearnz said:
Nah, he's asking @InstrumentOfPeace if *he* has any leftover parts he can send to you.

Broken rockers definitely explains the lack of go!

Looks like the crankshaft might have been turned while there was no timing belt installed? If there's no timing belt you must not rotate the crankshaft from TDC.

You should remove, wash with solvent, and closely inspect the rest of the rockers, checking for cracks, just in case there are others that are waiting to fail.

When you swap the rockers out you'll have to use a torque wrench to tighten the rocker shaft bolts (the ones with "10" in your picture). As the bolts tighten pay attention to how they feel. If one (or two) feel squishy as they tighten, like you're screwing them into cheese, then the threads in the head might have stripped out from the impact that broke the rockers. The threads can be easily and cheaply repaired in place using a heli-coil repair.
Click to expand...

When I removed the crankshaft bolt using the starter to loosen the bolt I recall turning it one revolution to put all 4 "pulleys" back into timing alignment since I can not turn counter clockwise, from here I removed the timing belt, I don't remember turning the crankshaft with out the belt BUT I might have done it I am not sure. In any case this is a big lessons learned for me. I only learned now that you can not turn the crankshaft by it self, I don't remember reading this on the manual or the threads. I want to thank everyone for your help I will continue to post the next chapter, I am great full that this mystery is solve..... onward to the next one.
 
sck_nogas said:
You are BOTH in Los Angeles area, so it's not that far of a reach. Since I'm in San Diego and recently played with my rockers, I could also help if timing is right.
Click to expand...
Thank you, I am getting together with InstrumentofPeace tomorrow to get the parts.
 
InstrumentOfPeace said:
@Growlerbearnz Are rockers & the camshaft usually mated? Meaning they wear into one another. So if you buy a new camshaft then buy new rockers? Or if you get used, take the set including the shaft? ... or should he just take the entire top end?
Click to expand...
Great idea, Me and IinstrumentOfPeace are getting together today to pick up the parts, I will talk to him about taking the whole top end, I am also concern that something else might have broke on the top end like the valve stem. My plan is to install the camshaft and rocker assembly and test run the engine. Hope I don't have to go further than that
 
Sorry I am new at this forum I think InstrumentOfPeace actually suggested the above. thank.
 
InstrumentOfPeace said:
Are rockers & the camshaft usually mated? Meaning they wear into one another.
Click to expand...
Not on the 4D56 with roller-tipped rockers. You can mix and match rockers and camshaft without any consequences (as long as you put the intake rockers on the intakes and exhaust etc...)

I believe early 4D56 (or 4D55?) had rockers without rollers, just a sliding metal pad. Now *those* will wear together and you wouldn't want to mix and match them.
 
Growlerbearnz said:
Not on the 4D56 with roller-tipped rockers. You can mix and match rockers and camshaft without any consequences (as long as you put the intake rockers on the intakes and exhaust etc...)

I believe early 4D56 (or 4D55?) had rockers without rollers, just a sliding metal pad. Now *those* will wear together and you wouldn't want to mix and match them.
Click to expand...
Awesome. So just pulling a few rockers and he should be good to go.
Are there any other parts I should pull that may have been damaged by that exploding rocker?
 
InstrumentOfPeace said:
So just pulling a few rockers and he should be good to go.
Click to expand...
Well now you've cursed it. ;-)

I would bring along the rocker shaft and all the rockers, just in case. And inspect the old ones very carefully. The rocker shaft is brittle and doesn't like exciting events, so it might be waiting to crack. Also inspect the hold-down bolt threads, looking for any aluminum in the threads that would indicate a stripped thread.

I would also turn the engine over by hand a bunch of times, feeling and listening for chunks of smashed rocker that might have been caught anywhere. Mostly the shrapnel will wash down into the sump, but you don't want any pieces caught up in the valve springs.

Maybe while the rockers are off give the head a damned good clean, get rid of all the oil so you can see any chunks.
 
Growlerbearnz said:
Well now you've cursed it. ;-)

I would bring along the rocker shaft and all the rockers, just in case. And inspect the old ones very carefully. The rocker shaft is brittle and doesn't like exciting events, so it might be waiting to crack. Also inspect the hold-down bolt threads, looking for any aluminum in the threads that would indicate a stripped thread.

I would also turn the engine over by hand a bunch of times, feeling and listening for chunks of smashed rocker that might have been caught anywhere. Mostly the shrapnel will wash down into the sump, but you don't want any pieces caught up in the valve springs.

Maybe while the rockers are off give the head a damned good clean, get rid of all the oil so you can see any chunks.
Click to expand...
The hold down threads looks good, cleaned it and removed aluminum chucks. Thinking of changing oil in case metal chucks made their way down. ThxE1757FD4-D2AE-4922-B855-34C9039C90E9.jpegE48C55AB-8CDD-43EB-81A5-23FC985F7ED0.jpeg
 
Nulla said:
The hold down threads looks good, cleaned it and removed aluminum chucks. Thinking of changing oil in case metal chucks made their way down.
Click to expand...

A quick check while you have the rockers off: lay a straightedge along the tops of the valves. They should all be about the same height. If one is vastly higher or lower then you have an issue, but if they're all within about 1mm then they're probably fine.
 
Growlerbearnz said:
A quick check while you have the rockers off: lay a straightedge along the tops of the valves. They should all be about the same height. If one is vastly higher or lower then you have an issue, but if they're all within about 1mm then they're probably fine.
Click to expand...
I did the straightedge it is perfectly straight. do you have suggestion to remove small pieces of aluminum that might have made it down the cylinder head holes? I am thinking of pouring oil on holes to flush them down, do you think this is necessary? thx
 
Rocker Arm are suppose to arrive Monday. Meanwhile I am installing the egt probe, I don't have a EGR valve so installing on the plate is not an option. It is also very difficult to install on the manifold at entrance to the Turbo for the most accurate reading. I am installing the 3 in 1 Glowshift. thxegtmanifold.jpeg
 
Nulla said:
I did the straightedge it is perfectly straight. do you have suggestion to remove small pieces of aluminum that might have made it down the cylinder head holes? I am thinking of pouring oil on holes to flush them down, do you think this is necessary? thx
Click to expand...
Anything you can do to move those metal chunks down is worth doing. Compressed air maybe? Just cover the other holes with a cloth, the compressed air will go into the sump and come back up the other holes, carrying oil with it! Could get messy.
The rockers are cast iron, so you might use a slim magnet on a stick to probe into those drain holes, in case any large chunks are stuck halfway down.

I would also change the oil before starting the engine, and change it again after just 100km. That'll get as much of the metal out as you can.
 
Growlerbearnz said:
Anything you can do to move those metal chunks down is worth doing. Compressed air maybe? Just cover the other holes with a cloth, the compressed air will go into the sump and come back up the other holes, carrying oil with it! Could get messy.
The rockers are cast iron, so you might use a slim magnet on a stick to probe into those drain holes, in case any large chunks are stuck halfway down.

I would also change the oil before starting the engine, and change it again after just 100km. That'll get as much of the metal out as you can.
Click to expand...
FYI my rocker arm are aluminum. I will change the oil and shoot some compress air in the holes. thx
 
Got the engine running today. Sounded great. Thanks everyone for your help. The 3 in 1 Glow Shift Boost, EGT and Temp gage is also installed. Now I am trying to figure out the next thing. What are you using for an oil catch can? thx
 
Now that I got the engine running and been riding around town, how can I lift the front a couple of inches to accomodate slightly bigger tires. Is there a lift kit I can source. thx
 
Nulla said:
Now that I got the engine running and been riding around town, how can I lift the front a couple of inches to accommodate slightly bigger tires. Is there a lift kit I can source. thx
Click to expand...
Re-torsion your torsion bars and that should give your nose a lift. If you are already at maximum, then you'd need to look at lift kits.
 
You must log in or register to reply here.
Top