cylinder head problem

[chrissev]

So I took the injectors out of my 1.6TD cylinder head again, as they had been leaking compression around the bases where they are screwed into the head (as well as some diesel bubbles).  I found one injector really badly carboned in place (and the heat shield was very hard to get out), one injector hole was full of diesel liquid, and one was slightly carboned.  The fourth was in perfect shape.  So I scraped all the carbon off the sealing surface where the heat shield seals against the cylinder head (on the three bad injector holes) and had a close look at this surface.  I found:  one badly pitted at the bottom, with raised metal in some places and holes in others.  This one was leaking badly around the base of the injector.  I now know why I guess.  The other two were also pitted and uneven, but not as bad.  The fourth one is perfect and I can really see how bad the other three are when I compare them to the fourth.  So, if you were confronted with a cylinder head in this condition, what would you do?  Am I now in the market for a used rebuildable turbo cylinder head, or can a machine shop fix this up for me?  I put the injectors back in for now with lots of anti seize compound around the threads to try to seal them up but this is of course only a temporary solution to the problem.  

Chris

[janb]

in most cases this can be fixed at machine shop with a fresh spot face, find one that is creative, familiar with VW-d's and confident they can do it (and look at some of their equip, and machine work to assure they are not blowing smoke, or get references)  It really is not tough to do, but not 'conventional' either.  They may need to make up a special tool, but thats not so unusual ...  Someone who does lots of vw-D heads will have a cutter for this laying around their tool box.

You want to be sure that there are not ignition craters eroded somewhere.  Injectors can shoot a bogus spray, and end up burning a horizontal hole in injector seat area.

Never sieze is not a very good sealant.  I like to use a hydraulic fitting sealant for injection issues (but if you have to use a sealant, somethings wrong) the HYD stuff is made to seal 2000 psi., but it is not too high temp.