81 CY 1.6td Broken Glow Plug tips 3 tips are broken, some

[fighting_First]

worse than others.

What can should I do about these GP tips running loose in my engine and turbo? Will a broken tip pass the pre-cup chamber?

Why 3 broken GP tips not all 4?

We ran a compression test and came up with 17bar (240psi) across all cylinders. Rings were replaced less than 1000miles ago along with the rebuild. Im not sure how good the tester works but all cylinders are the same pressure, including the undamaged glowplug cylinder.

What is good compression for a 1.6td

Im guessing my turbo needs a close look, 3 pieces of metal flying around 1 of them had to make contact with the turbine shaft. Anyone have this problem?

I was 100km from home running hard at about 140kmph when the temps shot up, engine started "running away" and a cloud of white smoke. I cured the runaway by dumping it into gear but the engine would not hold an idle.

I left the car at a mechanic, returned 1 week later and drove it home. The car would not start without a pull jump, runs fine just doesnt start with the key.

If the engine is running and there is on strange noises, did the stones pass?

Run away is still present after 140kmph.

This is a follow-up to the link below: (huge thanks to everyone)

 http://vwdiesel.net/phpBB/viewtopic.php?t=16709&start=15&postdays=0&postorder=asc&highlight=

[theman53]

I have heard that you should have 400 to 499 psi for spec...I have had an engine that ran at 320-330-290-250. So I would say there is a big range that you can run them, but 240 is pretty low especially for a fresh engine. I would say that your valves are trash if the gp tips broke off in there. You can loose compression if your valves aren't sealing. If it were me I would take the head off and see what kind of nasty is in there...if it didn't have the bad compression and hard starting I wouldn't worry as much but that is just me.
You said rings were replaced...did you hone or bore it? if you just threw some rings in there that could be your problem as well.

[Mark(The Miser)UK]

So I assume your current starting problems are even with new glowplugs.

I think that 3 out of 4 glowplugs melting and not 4, is simply happenstance. :idea:

 

[ You were obviously for that period of time operating right on the edge of melting and not meltng the plugs. It is my opinion that the turbine may be OK. Remember the 3 or more chunks are not the product of  a break off from a clash, like  a piece of valve, but a red hot drip. I think once in the form of a mobile drip it would stay red easier than when still attached to the heatsink of the  glowplug, so it/they may have passed through the turbine still red , and if hitting the  turbine a lot softer than the blades, which although can become red themselves are designed  not to melt... See what  I'm getting at? :?

The compression results  are low, but uniform, and not out of the range of some engines happily chuntering around out there :shock:

Interestingly when measuring a diesel, how do the compression testers take account of the significant additional volume created by the 18" tube and the bourdon bit too?
I've thought of putting welding wire down the pipe to fill the gap in. :idea:  :idea:  

[Maybe, thinking about it, it's important to have the gauge release valve right next to the 'well-stuffed' injector dummy and not at the gauge end... I have a feeling my gasser one  has it by the sparkplug, but the diesel one has it on the wrong end  up by the  gauge]  :shock:

Perhaps some have re-ringed for nothing :roll:  

[Mark(The Miser)UK]

Interestingly when measuring a diesel, how do the compression testers take account of the significant additional volume created by the 18" tube and the bourdon bit too?

My tester has a check valve right at the tip of the faux injector.  Because of that, the pressure in the tube increases any time the pressure inside the combustion chamber exceeds the pressure inside the tube.  That is why it is important to wait for the highest reading as that is the actual compression pressure for each compression stroke.  That is also why a simple gauge and tube is useless for the task.

Andrew

Mine is a Snap-on. I'll have to recheck it's position

[Mark(The Miser)UK]

:idea:  :idea: Still not gone to the shed, it's 2 am here, but I did a key word search. first two on ebay are valved at the wrong end! One chap has 96 for sale. What a cluster f!  My excuse for mine,  :roll: if I'm right in thinking its like the others, is I bought it for $10 at one of our car boot [trunk] sales :idea:  :idea:
EDIT
They are all like it, so the only possibility is that the injector end has a one way valve incorporated. I'll look at mine tomorrow

[Mark(The Miser)UK]

Ha ha,  as you said it I was writing it.  :lol:  

[fighting_First]

figure out some of the real issues on my car. With regard to the Misers topic on the glow plugs, NO I have not replaced them as of yet. I pulled the GPs on Saturday and was so beside myself with the findings I left the car alone.

What causes the GPs to break during a run away?
 
One more thing, the starting issue started before the run away happened.
After the rebuild, the engine started perfect a week went by and the starting issue began and got worse each day until no pulse at all. Then I decided to get brave driving a bit to far and fast and bam the engine started running away.

Guessing but I think the runaway is caused from this hydraulic head swap and my preparation prior to installing it. I only glued the oil return in the head not tending to the block. Others pointed out that both sides must be sealed, could this cause "runaway"?

The lower part of the block ie the oil pan gasket and dipstick are wet, major oil loss, 2 liters after driving 200km.  

Does that make sense?

Thanks,
Sean

[Smokey Eddy]

What causes the GPs to break during a run away?

i asked that exactly and i believe libbybapa reckoned to me, and i agree, its just the amount of fuel (so heat) over such a period of time really screws with ceramics

[theman53]

Just wondering...Did you do the compression check with the new glowplugs in? It would make a huge difference, but I am sure you did. I assumed you had new glow plugs in for the hard start problem. If they are getting that hot either they aren't shutting off or a fueling problem I would guess.