PD Head R&R Photoshoot - BEWARE! LOTS OF BIG PICS!

[myke_w]

I figured I'd share this job with the community, since most folks haven't had the opportunity to see the internals of a PD motor yet, including me The owner brought me the car and we agreed that a used head in good shape would be less expensive alternative for him versus a new cam, lifters, valve guides, machine shop work, valves etc.

Here goes:

Picture of valve impact on the piston, #4 exhaust valve hung open because of excessive deposits from a  badly worn valve guide on #4 intake, then debris floated around in the combustion chamber and smacked the piston, crushing the top compression ring and scoring the cylinder wall.


Scored cylinder


Crazy split intake for increasing EGR flow no doubt


EGR flow valve visible


PD head from above


#4 intake lifter is trashed


Note the wear on the #4 intake lobe


Stock kp39


Fuel supply and return galleys and injector harness plug


The supplier of the head dropped it on its edge near the tensioner mount, we had to have the machine shop file it and check it to be sure it was still usable


The intake egr split continues into the head


A bit messy


Notice the lack of valve reliefs in the pd pistons, I assume this must make it a higher compression motor.


Empty hole


Old head, more forensics pics to come on disassembly


Roller rockers.. wait, I didn't know we were building a small block Chevy


Tapered cam just like every other vw diesel


Underside, nothing special here


Ball hone, I prefer it over the single arm stone hones, the best option would be a dual arm stone hone to avoid any tapering of the cylinder, but on a light hone like this, it's not a big deal


Getting the angle right is tough


Looking into the hole, still a bit of scar showing, but not enough to feel it with the finger test, more or less a mark and not enough to stop the show.


note the ragged surfaces where the cap bolts on, it's "industrially cracked" for a perfect precision fit, also notice how there are no locating lugs on these bearings like on all previous gas and diesel models


bent up piston crown from debris in cylinder, crushed #1 ring into place and scarred cylinder wall


New / used piston and rod going into #4


Ring compressor mounted


Rat turds!


Piston fitted


Glow plugs, new ones come on cardboard because PD ones are ceramic, very easily broken


head in place


turbo mounted in place


naked belt drive


crank lock in place (required tool in this job)


I slid the belt around the lower pulley, then forward of the roller, then around the tensioner (hadn't put the nut on yet) and then worked it around the rear of the cam gear


then up over the water pump, easy money!


back together

[RabbitGTDguy]

pics no worky worky on my end But, it'd be cool to see!

Joe

[lord_verminaard]

They worked for me if I right-clicked and selected "view image"- kinda a PITA.  

That split-intake is one of the dumbest things I've ever seen.  And it even goes into the head!!!  It looks like the intake tract has half the area that the TDI's do.  I wonder if all PD's have this design, or if it's just the USA's bastard version.

Brendan

[myke_w]

I agree the slit intake thing is dumb, I'm not sure what the point of it is though, because backing up intake pressure inside the manifold would actually reduce egr intake, because there would be positive pressure at the valve.

Any way you cut it, it's the first thing I'll port away when my head comes off in the future, they actually have a valve in the egr cooler too, the intake butterfly is operated off a diaphragm off the passenger side of the intake. I'm pretty sure the european pd's have no such divisions.

Amazing that they still get all that power out of them.. Imagine how it would perform with all that obstruction / restriction gone.  :twisted:

[RabbitGTDguy]

Pics worky worky now

Its amazing the engineering that goes into things like this and then yes...what power they are able to pull out of them with all those "restrictive" elements. It would be QUITE impressive to see how such a motor would run without those restrictive items in place, the potential power output, etc...Quite.

In a way though... doesn't it feel slightly cheapening to see things such as "industrial cracking" on the caps on the PD motors? Though the pontential benefits can be seen.  No reference markers, etc... or is it just me?

Joe

[myke_w]

Industrial cracking seems like a good idea to me, if it started as one piece, that means the fit is more precision than 2 machined pieces going together, although there was no problem with the way it was done before, which must mean that the only reason to so it is cost savings. It's definitely as precision fit as you will ever find, a one off if you will..

[MikkiJayne]

What an amazingly overcomplicated thing that is  :shock:

European PDs are equally strangled by the EGR. Some models exhibit a really annoying cough going from coasting to accelerating, and apparently its because the poor thing is breathing so much exhaust gas. It's possible to mod the engine to make it go away, but the dealers won't do it because then it doesn't meet the emissions specs. There have been thousands of warranty claims for it in the UK, and some people have even returned the cars because the dealers won't fix it! I think it was discussed a lot on TDIclub for a while.

Even so, a chipped PD goes like a greasy weasel so I'd still have one  :wink:

[jtanguay]

awesome! pics of the dogbone and how it connects.

[vwmike]

So, what're you doing with the injectors out of the old head?

[myke_w]

no plans yet, was thinking maybe have kerma hook them up and drop them in my pd motor

[vwmike]

I have a set of Bosio Race nozzles for my PD150 and will probably end up putting them on my PD150 injectors unless I can get a set of BEW injectors....That's kind of where I'm at.