FE400e broken valve adjustment bolt

mrothwell · Mar 11, 2013

Several months ago I posted about my 98 FE400e locking up with a THUNK. I haven't had the time to dive into it until this past weekend. Here's what I found:

One of the intake valve adjustment bolts broke. I found the end that pushes the valve, but the bolt is just plain gone. I've pulled the clutch cover off, and I would think that is the only place that it could be, but it's not there.

I can rotate the engine (with a wrench on the flywheel) about 300 degrees, then it has a hard stop, either way. It has compression, and it rotates thru top dead center and is actually stopping near the bottom of the stroke.

I cant rotate the engine enough to expose the master link of the cam chain, so not sure how to even pull off the head right now.

Any ideas where to go now??

Idle · Mar 12, 2013

Easy, break the timing chain anywhere convenient and get a new chain or a rivet master link when ready to reassemble.

It's got to be in there somewhere. You're missing the top of the screw and the nut correct?

mrothwell · Mar 12, 2013

OK - here's my update.

I found the nut, it had dropped between the timing chain guide and the cylinder wall, where it could have lived forever not causing any problems, but no bolt. I figured that the bolt must have gotten in the gears behind the clutch, so I pulled off the clutch and gear, but nothing, and the crank would still only turn about 300 degrees. So, I knew that it had to be inside the crank case. I figured out how to get the master key of the timing change to a place where I could get it off and pulled the head and the jug. Then I pulled the piston to get it out of the way. Found the bolt, or at least parts of it, stuck in the crankshaft gear that drives the counter balance shaft. I got most of it out, but there is still a small chunk wedged in there so tight I couldn't get it out because it's so hard to get a good angle on. I'll figure out how to get it out tonight.

I'm still concerned that there may be some other small pieces in the crankcase, so I'll send down a magnet to see if I can fish anything out.

The good news is that my piston, rings, cylinder wall, valves, valve seats, etc are all in great condition. No slop at all.

If you look at the far left of the picture, you can see the piece of bolt wedged in the gear.

jimmythehat · Mar 21, 2013

that looks messy, goodluck! and tighten your valve clearance lock nuts!

FE400e broken valve adjustment bolt

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