Head and sump off, this is what I find!

[wil892]

Have just tested the bits with a magnet. The smoother curved bits can be picked up with a magnet, but the rougher mashed up pieces can't.

I have to say I did wonder how the bits from the int shaft got past the bearing, especially as there is no scoring on the bearing its self. Although as to where the whole lip has disappeared to is quite worrying.

I have noticed though that the outer int shaft bearing on mine looks thinner than the one in the thread posted by Quantum TD.

http://www.vwdieselparts.com/forum/viewtopic.php?t=8480

[wil892]

My bad, have just found the lip in the sealing ring in one piece.

Bit worried now. This engine is perfect apart from this mysterious metal!

and BTW whats the 'race on the vac pump side', easy to sort?

[zukgod1]

I was thinking it could be the area where the bearing is pressed in on the far end of that shaft.

Can you get us a better pic of the smooth surface from one of the pcs?

[wil892]

Bit confused.
You want a pic of the outer bearing or the one inside the block?

[zukgod1]

I wanted to see some better pics of the pieces of metal.

[wil892]

Ok, taken a couple more pictures, closer this time. I'm taking the block and head to a good VW specialists to be checked, possibly honed and reringed and then put back together.

[zukgod1]

Wow!

So you have the valve cover off and everything under there is ok? No missing/ mashed lifters?

[wil892]

No, lifters and cam are fine. Apparently the engine was running absolutely fine before removal.  

The oil pickup had a couple of bits in it, other than that just these bits in the pan. I can't say I've had a huge look through the bottom end as I'm a bit afraid to start undoing the bolts  in it.
The bits do look like bearings as they have slight wear to the inside of them. But as I said earlier i can pick them up with a magnet.

[zukgod1]

They look to thick to be pcs of bearing to me but..

I guess you better just tear into it.

Hopefully you find they are left over from a previous issue that has already been addressed.

[Quantum TD]

I've heard stories here in the US, of people taking their transmissions in for service, and having a corrupt mechanic come out with a trans pan full of metal bits to show the customer.

Not saying that's what happened, but it's either that, or someone crunched a lifter on this car at some point, and then never dropped the pan.

[zukgod1]

These close up pictures do look like lifter parts dont they?




I hope you find nothing and these are from a previous issue already delt with as I mentioned earlier.

[Baxter]

Oil pump drive guide bearing? the non ferrous parts?

Parts of Vac pump?

[wil892]

I've now pull the camshaft and lifters, and while inspecting the lifters have notices that one is different from the rest. The odd one out has INA stamped on its under-side which the others don't. The shape of the underside is also slightly different to the others.

I'm guessing this might have been the cause of the metal. Three pistons do have very slight 'kissing' marks on them from valves, but none more so than the others.

I said in another post that the head is an exchange unit from VW as it has a stamp on it, but the wierd thing is that the bores on the engine still have all the honing marks to them, leading me to believe the engine has been rebuilt (came out of a car with 175,000 miles). So possibly since rebuild the timing jumped? breaking a lifter, which was then fixed?

[Quantum TD]

I've now pull the camshaft and lifters, and while inspecting the lifters have notices that one is different from the rest. The odd one out has INA stamped on its under-side which the others don't. The shape of the underside is also slightly different to the others.

I'm guessing this might have been the cause of the metal. Three pistons do have very slight 'kissing' marks on them from valves, but none more so than the others.

I said in another post that the head is an exchange unit from VW as it has a stamp on it, but the wierd thing is that the bores on the engine still have all the honing marks to them, leading me to believe the engine has been rebuilt (came out of a car with 175,000 miles). So possibly since rebuild the timing jumped? breaking a lifter, which was then fixed?

Sounds like we've solved the issue as to the origins of the metal bits. You still need to address the intermediate shaft. I'd say it's a 99% probability that the metal hunks are from a shattered lifter: likely caused by a piston hitting a valve.

[Mark(The Miser)UK]

What could have caused the I/S damage?]
My theory is if the driven shaft encounters a binding vaccuum pump then the mesh thread will apply tremendous longitudinal force like screwing in a bolt. A cast iron bolt gathers no moss ...oops is brittle :idea: