803A engine help

[spark500001]

Hello, we just bought a 2010 MEP803A generator from Gov planet it has 100.9 hours on it. it was bought as non-running but, in the video, it has oil pressure. we are trying to get it operational.
we cleaned out the fuel tank and all the IP fuel pumps and installed new fuel injectors plus filters. it will turn over (good cranking speed) slight amount of white smoke shows. in further investigation we all the intake rockers were cracked, and pushrods are bent. the crankshaft and camshaft marks appear the line up.

we replaced all rocker arms and pushrods. another attempt to start was tried and all the intake rockers are cracked again.

does anyone have any idea of where to go next or what TM we can look at ?

Thanks for any help or suggestions

 

[Ray70]

When you tightened the rocker arms did you follow the instructions and allow the lifters to sit and bleed down for 1/2 hour , then rotate the motor by hand and let it sit again before cranking the engine?
If you don't the lifters will be pumped up, causing the valves to hit the pistons and bend the pushrods.
I can't say I have ever seen cracked rockers, but I've seen plenty of bent pushrods.
If you need more pushrods and/or rockers I should have several sets of used ones available.
You need the engine TM available here:

https://www.steelsoldiers.com/attachments/tm-9-2815-253-24-pdf.888635/

 

[spark500001]

thanks Ray, we followed the TM when we installed the new rockers and pushrods . is it possible that the gear has moved on the camshaft ? the crankshaft key is still in the slot so that was the only thing we could think happened at this point.
thanks for your input

 

[Ray70]

Anything is possible. I believe the LPW4 gear is held to the gear with a slot in the cam and tang on the gear. Perhaps the ears of the slot in the cam have broken off. Only way to know if to pull it off.
You could try pulling the #1 injector and valve cover and stick a screwdriver of rod down the injector hole so its sitting on the piston.
Crank the motor to TDC and see if both valves are closed as you pass by BDC and are still closed as you pass by TDC.
The exhaust valve should start to open as you approach BDC again.
This is a crude test but if the cam is way off it should be pretty obvious to see.

 

[spark500001]

Thanks again Ray we will give it a try

 

[spark500001]

Thanks again Ray we will give it a try

Also we had pressure coming out the intake and suction on the exhaust manifold

 

[Ray70]

Also we had pressure coming out the intake and suction on the exhaust manifold

That's a sure sign that the valve timing is incorrect.
It sounds like you should just go ahead and pull the timing cover off and take a look..
See if there are signs of someone else being in there previously.
Perhaps someone assembled things incorrectly ( timing gears improperly aligned ) or perhaps something has broken.
AND.... make sure the engine is cranking in the right direction!
There is a starter for the MEP-701 ( IIRC) that looks exactly the same as an 802/803 starter. It bolts up the same, but cranks in the opposite direction!
I once ran into the same thing ( pressure in the intake and suction on the exhaust) while working on a 701. Turned out it was because the starter died and the replacement I had on my parts shelf ( which I think was for an 802/803 ) spun in the opposite direction.

 

[Mark T]

Thanks for all the Help Ray
Me and Spark500001 are working together on this mep803a

 

[spark500001]

Thanks again from Mark T and I you’ve been a big help

 

[spark500001]

We removed the front cover and the crankshaft key appears to be intact and in the proper spot. the timing marks are lined up when the engine is rotated . when we watched the rocker arms they seemed to be around 90 degrees off what the timing marks show .also there are spots when rotating the engine where it gets tight like we have interference . the engine doesn't looked like it was taken apart before . we are now scratching our heads of what is wrong.

 

[Ray70]

Did you check the camshaft to see if the cam and gear are intact and aligned?

 

[2Pbfeet]

We removed the front cover and the crankshaft key appears to be intact and in the proper spot. the timing marks are lined up when the engine is rotated . when we watched the rocker arms they seemed to be around 90 degrees off what the timing marks show .also there are spots when rotating the engine where it gets tight like we have interference . the engine doesn't looked like it was taken apart before . we are now scratching our heads of what is wrong.

As @Ray70 points out I would suspect that there is something amiss with the camshaft, probably its gear.

To me, the "rocker arms they seemed to be 90 degrees off" and "...there are spots when rotating the engine where it gets tight like we have interference..." are consistent, and both point to doubting whether either crankshaft key or the cam gear ok. When they are lined up, where is cylinder #1 relative to TDC? At this point, I would verify by removal that cam gears are correct. I would also consider pulling the head, and seeing if the interference goes away. I suspect it will.

While I like @Ray70's suggestion of the 701 reverse direction starter, I don't see how that would generate interference.

All the best,

2Pbfeet