Diagnosis needed! Poss bottom end / flywheel?

[Teds_Wagon]

Hello,

So the car has started making a noise like its eating itself from the inside. Can anyone determine what it is from the video?
It sounds like something has sheared off and is now free to smash its way around the bottom of our engine/box. Has anyone had anything similar?
Bit of background, cars been sat for years and only just brought back to life, its had a recent service and we have found the actuator has a missing retaining nut and as such is letting boost creep past, could this cause it?
Could the dual mass snap/fail causing this sound?

Any suggestions will be hugely appreciated


https://vimeo.com/199297540

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[M-R-P]

What video?

[Teds_Wagon]

Ooooh, it hasnt uploaded let me try again 😂

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[Teds_Wagon]

https://vimeo.com/199298889

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[Teds_Wagon]

is it now view-able? It was being ££££e on tapatalk so have uploaded on laptop instead

[Doingitsideways]

No joy Fella.

[Teds_Wagon]

Any way i can upload it differently? I can view it when looking on laptop?

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[M-R-P]

Upload to YouTube and hit the share button. Click "copy link" and past it to the reply window here.

[Teds_Wagon]

Upload to YouTube and hit the share button. Click "copy link" and past it to the reply window here.


https://www.youtube.com/watch?v=Mk6-OGyLkuM

Now uploaded to youtube!!
Thanks for the above info

[Doingitsideways]

Sounds like it's runnng on three?
Could have mullered a rod I suppose if it's ran big boost.
Have you compression tested?

Exhaust manifold leaking too from the sounds of it.
You'd be surprised at the wierd and wonderful noises that can come from these.

[Teds_Wagon]

That was the 1st start in a few weeks, we took the pcv system off and de-gunked it. We could barely push a needle through what was meant to be a 8-10mm pipe!!! The manifold we know has a big blow but the sound at the end is what worries me the most when the camera is down at floor level. Could the dual mass shear and make a racket like that? Or more likely the bottom end?
Its really hard to determine with a loud blowy manifold though..

[Doingitsideways]

I'd do a compression test just to see what's happening. Would be a good idea anyway with an engine that's had long periods of non running.

Then I'd sort out the exhaust, so you can at least hear what's going on.

DMFs do fail, but never had one go personally, so can't help you.
Many folk replace them with a single mass.

Does the idle even out?
If not, then you'll get all sorts of bangs and rattles with it bouncing around.
A failing DMF would definitely feel the brunt of uneven firing through the crank.

[Dangerous Dave]

I once took the gearbox off my 940 and removed the flywheel to change the rear main seal. I found one of the six bolts around the RMS (in the pic below) had come loose and had been chewed up a bit.

https://www.volvoclub.org.uk/faq/ImagesProcedures/EngineIntShaftPlug1.gif

It's a possibility, but equally could be something more catastrophically imminent.

Also could be a loose bolt/bracket around the bellhousing area which is rattling/squeaking. Best check everything is tight

[Teds_Wagon]

Thanks for replies chaps, will have a look at the above, then compression test, then sort the mani blow. Really hoping its a gearbox issue as had planned to increase boost so could be seen as a blessing in disguise.. Fingers crossed!
Any other info/similar experiences massively appreciated 🍻

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[Dangerous Dave]

Thanks for replies chaps, will have a look at the above, then compression test, then sort the mani blow. Really hoping its a gearbox issue as had planned to increase boost so could be seen as a blessing in disguise.. Fingers crossed!
Any other info/similar experiences massively appreciated 

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Another thing to check is the starter motor, sometimes the gear can get stuck forward (still engaged with the starter ring) especially if it has been sat for a few years. Easy to check, just unbolt the starter motor and check it isn't stuck or the mechanism is clean and the operation is smooth.

[Doingitsideways]

That's actually just reminded me, I had a thrust washer/release bearing completely disintergrate years ago on my 940TD.
Result - lots of squashed ball bearings scattered around the bell housing.

[Teds_Wagon]

That's actually just reminded me, I had a thrust washer completely disintergrate years ago on my 940TD.
Result - lots of squashed ball bearings scattered around the bell housing.

Oooooooh sounds nasty!!! what sort of sound did it give off if you can remember back?
I ask because ours sounds as if its something smalls beings thrown around making a tick tick tick. Sometimes it will go BANG then the sound will disappear as if whatever's dislodged has found a temporary home, only to again dislodge itself and start over again. The sound of metal on metal does not fill me with confidence!

[Doingitsideways]

Kinda like you describe really, was blood curdling when something caught!

Giveaway would be vibration through the clutch pedal though.

[Teds_Wagon]

So we did a compression test at the weekend...
Spark plugs were dirty but ok.
10ish to 11bar across all four!
Exhaust manifold 2 of 4 gaskets working.. Lots of carbon build up
Now in the process of separating box and engine.. finger crossed!

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[Dangerous Dave]

Good luck!

Eagerly awaiting the result!

[barkster1971]

get rid of the t piece ££££e metal thing between the intercooler and throttle body.

[Teds_Wagon]

https://uploads.tapatalk-cdn.com/20170211/bb32044a6e9f77b1ff3a523ed6fef527.jpg

I think we may of found the problem!

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[Dangerous Dave]

The bolt from around the oil seal?

I called it :D

[LeeT5]

https://uploads.tapatalk-cdn.com/20170211/bb32044a6e9f77b1ff3a523ed6fef527.jpg

I think we may of found the problem!

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Nah! That's meant to be there :hidesbehi

[Teds_Wagon]

https://uploads.tapatalk-cdn.com/20170225/7c5bfffdcc774a5a02c22053ec14c55c.jpg

So we decided on pulling the engine rather than trying to get the gearbox back on underneath the car with limited access. Plan now is the following;

- New clutch and/or flywheel (dogdish)
- Replace all pipework
- New actuator for the turbo
- Clean down and repaint block
- Wrap exhaust and downpipe

Will update soooon..

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[Dangerous Dave]

Maybe worth porting the exhaust manifold whilst it's off as from what I remember they are restricted at the collector.

Ported (though not pretty) vs standard
http://i.imgur.com/6xu3k8l.jpg

[Teds_Wagon]

We are definately porting all the above, ours has lots of inperfections in the casting so have gone through a few dremel heads already... Slow progress but we are aiming for completion by June

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[Dangerous Dave]

You need a carbide burr bit:
http://www.ebay.co.uk/itm/INDUSTRIAL-QUALITY-6MM-SHANK-CARBIDE-BURR-5-16-DIA-DOUBLE-CUT-SH-2-ROTARY-TOOLS-/371403436145?hash=item56795eb071:g:x8QAAOSwd0BVvxr t

Will go eat the metal a bit quicker, it's what I use for my manifolds plus it doesn't wear out quickly (had mine for years)

[Teds_Wagon]

So everythings bolted back together and the engine is back in the car. Two issues we have before it will start-
- Which way round do the hoses go into the inlet manifold?
- We are getting no spark from the distributor so will need to have a look into that..



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[woz]

Any updates??