OOPS part 2 from across the country

[R.O.R-2.0]

looks like those cups are not sticking up at all..

[theman53]

They are not.

I took the turbo off and inspected it. While rolling the head over #2 precup fell out. I tapped on #1 and #4 and they were loose. I think it must have been a precup issue. I put 3 peen marks into the head to help hold them and it still did this.

I talked to my machinist who did my block but not my head. He said he always machines them separately and NEVER puts them in if they don't stick out at least .002". I think this is the only thing I could have done differently. Made sure the precups stuck up further.

[rabbitman]

This scares me, I just did the HG on my rabbit and all of the precups where loose/easily removable. I peened 'em in and they felt pretty tight but I don't recall that they stuck out at all......

[R.O.R-2.0]

They are not.

I took the turbo off and inspected it. While rolling the head over #2 precup fell out. I tapped on #1 and #4 and they were loose. I think it must have been a precup issue. I put 3 peen marks into the head to help hold them and it still did this.

I talked to my machinist who did my block but not my head. He said he always machines them separately and NEVER puts them in if they don't stick out at least .002". I think this is the only thing I could have done differently. Made sure the precups stuck up further.

i went peen happy.. i must have peened the bores in 20 different spots, and around the edges probably 10 times.. maybe i went overboard, but i needed a small brass hammer to get the pre-cups back in the head after i did all my peening..

my pre-cups were tight in the head after i peened the bores of the cups..

[theman53]

I took the oil pan out and found about a piston worth of material in it. Block is done, the oil squirter and where it bolts into are gone. There is a little hole in the back of the block with a piece of piston in it perfectly covering the hole so I couldn't see it. The rod big end and crank looks fine amazingly, all rod bolts held up, all mains held up, so I am hoping that the crank could be saved as I had it machined for the TDI sproket.
Looks like new everything but a crank.

I heard from a friend of mine to try the sleeve retaining compound. I sell RT-09 ritelock, but loctite has it as 609-at almost 2x the price-  I don't know if it will hold up to the heat, but I don't know how hot it can actually get in that .001" gap. Some of the higher heat red loctite is high temp but might never come out without busting it...but I would rather trash 4 precups if I could buy new each time than have one fall and kill the entire engine.

[410]

I would have been quite surprised if the block had been salvageable.  Hopefully the crank is okay. 
Maybe [dare I say it], it's time to move to a tdi .  No precups to fall out .  I'm sure you'll be happy with the aaz though.  The bottom end torque is really nice on the aaz.  That extra .3l makes a big difference.  Let me know if you can think of anything else you need.