D24tdic strange noise etc

[slimlavud]

I bought another D24-engined car! I got a 1995 Volvo 940 TDIC auto estate with allegedly 100,000 miles on it - it looks genuine by the car wear etc.
But after I got it, I noticed a smear of red 'Hermetite' jointing compound on the edge of the fibre head gasket and found some cylinder head bolt wrench adapters in the rear of the load bay... never a good sign...
The car ran fine, started instantly, reasonable power, reasonable on fuel, uses almost no oil and a pint of water every 1,000 miles - no leaks or overheating though.

The one day after being left for 7 hours, it seemed to 'lock' and not want to turn over on the starter - just like one or more cylinders were full of a liquid. It started after another try and ran OK.
It now has fallen off in power and has a 'chuff/tick' noise from one cylinder - near the back I think. Still never gets hot or uses much water (done 350 miles since), sounds almost like a worn rocker (if it had rockers of course).

My questions are:

1. Could it have bent a rod and what I can hear is a piston scuffing badly in the bore?

2. Has anyone heard of a rod bending on the starter motor pressure alone?

3. Since the steel head gasket bulletin of 1996, are there any even better gaskets available?

4. Is the Elring gasket that some aftermarket dealers are selling a steel gasket or do I have to buy the real thing from Volvo/VW dealers?

5. Any sources for gaskets etc in UK that are steel gaskets and reasonable price?

I know diagnosing engines by email is like doctoring on the telephone but thank you for any ideas?

Simon, London, UK.

[RoyMacDonald]

The engine does drop off in power and become noisier if the timing goes out, the emission go to pot as well.

The head is prone to cracking but the engine can go on and on and on. My service guy has one with 665,000 on the clock.

You'll find out what the head is like when you fit a new gasket of course. I always used Volvo parts on mine.

[jor]

Sorry to hear about your engine woes Simon. I've tried looking up elring gaskets on brickboards etc, but without success. The people on the d24 list at tufts.edu wiould know for sure and could probably point you towards a diagnosis into the bargain. AFAIK the only people that would have the steel gasket would be Volvo or VW.
That said you presumably do not want to replace a gasket only to find that the noise and lack of power persist. I can recommend Wembley Motor Parts for cheapness / knowledge of older engines should you wish to fork out for a stripdown and might be able to help out should a piston or rod be required as there is a 740 bottom end in the garage (condition unknown).

jor

[RoyMacDonald]

I didn't think to recomend a garage but if you're in South London, First Diesel in Croydon know that engine very well, and will problably be abe to tell you what it is just by listening to it.

[slimlavud]

Thanks for all your thoughts and support, I think I am just being daft, the car is still going very well, the noise is probably just the damned vacuum pump after all...
And the pump timing probably does want checking, I shall do that very soon.
These noisy old buggers will just go on and on, I should stop worrying...

[RoyMacDonald]

When the vacuum pump became noisy on mine First Diesel diagnosed the problem by removing it and starting it up to see if the noise went.