Leaking injector damage

[TedV]

Another story to the “change your injectors as preventive maintenance.”   I am piecing together a mech. head 1.6TD motor, since they just aren’t that common here in TN.  I ended up with 2 mechanical heads suitable for TD. I sent the best looking one off to get rebuilt.  It only had 85K miles on it, no oil sludge, maybe one hairline crack between the valves, no cup cracks, all glow plug tips looked good except for some carbon, injectors came out easy, but three of the heatshield sealing washers seemed to be stuck in with carbon buildup, the other seat under the removed shield looked fine.  I was in a hurry to get it shipped so left the 3 shields in.  Found out when the machine shop got them out the head is eroded on 2 of the sealing lips with a 25% prognosis it might seal, recommending I get another head to be safe.  This shop has rebuilt a bunch of diesel heads, said they could spend some time clean up the seats and see if it holds pressure, just cost an hour or so of labor and have seen this from bad injectors.

My other mechanical TD head has cracked, and missing a few slivers, cups.  The small about 30mm ones you can’t find replacements for.  The “good” head has the bigger 32mm ones.

So, anyone have experience running a TD head with damaged seats under the heatshield?  Smart thinking says to find another head since I will be demanding some performance from this built motor.  Or, are there any small cup supplies floating around out there?

[vanagonturbo]

bad injectors causing a poor seal at the crush washer? I dont think so. Maybe I read it wrong.

[TedV]

injector hole seats burned badly, caused by leaky injectors I think was the wording used

[745 turbogreasel]

I burned a hole through the head into water with a leakey injector.  I was suspicious, so I put that injector in a different spot on the next head.
Guess what, blew that one too!

[TedV]

Ive seen pictures of burned thru heads and pistons from bad injectors.

Looks like I'm 2 for 2.  The good looking head failed to seal at injector and the head with cracked 30mm precups has an eroded seat in the head too :x   So I'm off hunting another mech 1.6TD head.  hope 3rd times charm.

Old school VW mechanic said folks around here used to treat the injectors like spark plugs, not replacing the heatshield washers and wouldn't torque them correctly.  :roll:

[745 turbogreasel]

I know Ford makes a cutter tool for resurfacing injector seats, not sure about Bosch.,...
But I redid one of mine and it seemed to hold.  I forget what exactly I did, maybe valve grinding paste on a washer?

[Mark(The Miser)UK]

I burned a hole through the head into water with a leakey injector.  I was suspicious, so I put that injector in a different spot on the next head.
Guess what, blew that one too!

Send that bad injector to Andrew so that he can test it and photo the spray pattern... I'm intrigued as to what a head cutting spray pattern looks like :shock:

[jtanguay]

I burned a hole through the head into water with a leakey injector.  I was suspicious, so I put that injector in a different spot on the next head.
Guess what, blew that one too!

Send that bad injector to Andrew so that he can test it and photo the spray pattern... I'm intrigued as to what a head cutting spray pattern looks like :shock:

lol probably a straight line instead of the cone shape? would probably look like a mini darth vader slicing  :lol:

[TedV]

I've cleaned up the seat using valve grinding paste and a heat shield and had it work well.

Andrew

that's on my list of ideas.  Haven't got the head back yet tho.  The other head with 30mm cups is grooved about .020" to .030" no use working on it until I find replacement cups. Since I'm pressed for time, may just get a head ready to run.

There are pics of a head on the forum here someplace with a hole into the far wall waterjacket.  I'd say the head cutting patern looks like a water jet or plasma cutter.  hhmm new idea for a cuttin tool :twisted:  :lol:

[burn_your_money]

I think that's my picture you're referring too. I'll try and find it in my mess of a photobucket account

[Zulfiqar]

while you guys are at it,

Can you measure the thread size of the injector - I bought a used head - with a cross threaded no.4 injector boss - Im planning to helicoil it

Any of you have a tap and die set handy.

[burn_your_money]

 :shock:

[Mark(The Miser)UK]

That's a shame the rest of the head's like new :lol:
Surely that's weldable :?: