Camshaft worn, lifters failed

I removed the camshaft from my standard Leon 1.9 TDI, 77 kW (105 hp), manufactured in 2006, with engine code BLS and 240,000 km on the odometer, because the engine suddenly sounded different. One hydraulic lifter was completely worn out, and several others were heavily worn. Only the lower bearing shells of the camshaft showed significant signs of wear. The engine was running perfectly before, started well, and the performance and fuel consumption were normal. So, I will now replace the camshaft with its bearing shells and hydraulic lifters. What surprised me were the wear marks on 3 of the 4 rocker arms on the camshaft. These 3 all show similar wear patterns. The rollers on the rocker arms show signs of wear, but don't necessarily appear defective (in my opinion). Should those also be replaced?
I've attached some pictures (I hope the traces are clear enough to see).

Hello,

Indentations on the lower camshaft bearing surfaces, on the timing belt side, could be explained by a timing belt that is too tight.
"However, this doesn't quite match the picture, as you can already see 3 worn bearing shells. The oil pressure/oil supply to the transmission is okay, and the PD elements were still tight?"

Best regards, Rainer.

All the lower bearing shells showed signs of wear. All the PD elements are still securely in place, and there are no indications of any play. Regarding the oil supply: I can only say that regular oil changes have been performed, and the oil level warning light has not been activated. When the oil filler cap was opened, the oil was swirling, and the shaft and other components were still well lubricated with oil when the valve cover was removed.

Are the sealing plugs present in the tilt lever shafts, or are they missing?

Normally, an error code will also be set for the "mass airflow sensor."

Hi Wutzi!

Interest question:
Which oil was used, and at what intervals was it changed?

The mileage isn't necessarily insignificant, but what kind of driving conditions was the vehicle subjected to?

Best regards from Munich!

Quote:

Normally, however, an error will also be set for the "mass airflow sensor"

.
Please provide clarification on that .
hg
Herbert.

Herbert wrote:

Please provide clarification on this . hg Herbert

Sure, here is the translation of the text from German to English:

"I am looking for the exact error message."

I checked the cam levers, and the cam lever on the timing belt side is missing a cover plug (is it possible to buy these individually, or only as a complete cam lever set?). The others are present.
I bought the vehicle with approximately 185,000 kilometers on the odometer, and it has been driven in a mix of highway, federal road, and city traffic. It has been driven mostly economically, but occasionally at higher speeds on the highway, and occasionally with a trailer (no recreational vehicle towing). The car has a service record, and before I bought it, it was serviced every 15,000 kilometers at various workshops (no indication of which oil was used). I have changed the oil every 15,000 kilometers and use Liqui Moly 5W30 (1137).

What surprises me is the condition of the camshaft lobe contact points on the rocker arms, and that the rocker arm roller seems to be in relatively good condition. Only one lobe shows no signs of wear.

Where did the missing sealing plug go? Could the marks on the tilting lever cams be related to it?

Best regards, Rainer.

Hello everyone!

...or even pieces of the broken hydraulic lifter.

Best regards from Munich!

EDIT: @HerBärt, "Chili" is referring to the following scenario:
Due to missing valve stem seals, the oil pressure in the cylinder head decreases, the hydraulic lifters do not receive sufficient pressure, the valves (especially on the intake side) do not open fully, and the air mass flow is reduced accordingly, which can trigger an error message from the engine control unit (ECU) – although this is not always the case.

Sure, here's the translation:

"Hello there,"
Could the marks on the rollers also be caused by excessive play in the rollers or the rocker arms (i.e., is the mechanism jamming)?
hg
Herbert.

Exactly, DieselBär, that's what I mean.

I always make my own earplugs and insert them. I believe the original ones are made of aluminum, but I always make them from regular round iron rods or screws.

Okay, I took another look at the cylinder head and found a piece from the hydraulic lifter, as well as a whole bunch of metal shavings. I can't determine how much metal was flushed out with the oil (or ended up in the filter). The metal shavings in the picture aren't all of them that I found, but it's about half of what I found (the rest fell away).
Error memory is empty.

Okay, the spare parts have arrived, and I've started assembling everything. Unfortunately, I can't find the torque specifications for the screws using the search function.
1) from the camshaft bearings.
2) from the toggle levers.
found. Could someone please tell me what it is?

Hi Wutzi!

1.) Valve cover camshaft: 8 Nm + 90° (1/4 turn).
First, attach lids 2 and 4 and tighten them diagonally, then attach lids 1, 3, and 5.

2.) Tighten the pivot arm axle screws: 20 Nm + 90° (1/4 turn).
First, tighten the two innermost screws, then the outer ones.

Good luck & success!

Best regards from Munich!

EDIT: Of course, replace the screws!!!

I successfully reinstalled the valve train and, of course, used new screws. I also removed the oil pan again and found the drain plug, parts of the hydraulic lifters, and a lot of metal shavings. The oil pan already has hairline cracks, and I have no idea why.
The PDE elements have also been newly installed and, after the entire assembly, include:
Timing belt kit including water pump, new hydraulic lifters, camshaft with bearing shells, one used rocker arm shaft, seals, oil filter, oil, a lot of screws, valve cover gasket, seal for the high-pressure pump, and a lot of work. Today, the engine started without any problems and sounds quite good. I can't perform a precise check because I don't have the diagnostic tool, but it's running for now.
Thank you for the instructions on "Adjusting PD elements," as well as the tips and torque specifications.

Finally, it's the weekend (and tomorrow I'll clean up the workshop).