Think this will buff out?

[Whitbread]

I've built over 50 1.9 tdi's and never had as much hassle combined as I've had in 5000 miles with my 1.6. Got the used 1.6td to drop into my caddy, rebuilt whole front end of truck, head gasket blows a month later, rebuild engine with aaz gaskets and studs, hydroplane and bump a curb a month later, replace strut and top mount/bearing and get alignment, 5 days later this happens. Mechanical AHU will be going in place of this miserable lump.

[theman53]

Welcome to my club. At least the block doesnt have holes all through it and looks rebuildable.

[libbydiesel]

That is the issue that swings me over to TDIs.  I have my own pics...

[Gizmoman]

Was it a stock set up or were you running tons of boost or other mods?

[RabbitJockey]

Sit it on a belt sander and it will be good as new

[92EcoDiesel Jetta]

What happened? Did the hydroplaning oversped the engine?

[smutts]

Ouch! That's brutal. Prechamber suicide?

[Whitbread]

Was it a stock set up or were you running tons of boost or other mods?

Stock parts with fuel turned up, 2.5" open exhaust, aneroid pin ground a little, and timing at .040". That was it.

What happened? Did the hydroplaning oversped the engine?

Was just cruising down the road at 55 in 4th gear and started hearing some really loud ticking/tapping. Pushed the clutch in, motor stopped immediately. Tried to crank it over on the shoulder and it wouldn't turn over. Called a buddy with a strap haha.

[Gizmoman]

Sorry for all the questions but I'm looking for reasons to keep working on the money bucket attached to my engine stand

How many miles on the engine?

Was it a stock VW head or aftermarket?

Do you have an EGT sensor/gauge and if so what is the highest temp you ever saw?

Have you ever overheated the engine?

[libbydiesel]

Gizmo, these engines can last a very long time.  Make sure your pre-cups don't have any minute cracks forming (you got new ones didn't you?).  Once it's running adjust the fueling so the EGTs are very safe.  You'll be fine. 

[ORCoaster]

I think there is an epoxy for the precups and yeah, just yank that there piston and slap it on a belt sander.  Good as new, use 600 grit and some machine oil to smooth it all out. 

Seriously a new head and piston will solve your troubles will it not? 

[Whitbread]

I think there is an epoxy for the precups and yeah, just yank that there piston and slap it on a belt sander.  Good as new, use 600 grit and some machine oil to smooth it all out. 

Seriously a new head and piston will solve your troubles will it not? 

Nope, the #1 injector was apparently bad and fuel washing the cylinder walls as there's a major wear ridge in the top of the cylinder. You can see it in the pic. There was only 3Kmi on the motor when this happened after the rebuild. The other cylinders obviously still have cross hatch and are perfect. To save this motor it would need bored and a new head. Thats alot more money than me tossing together a mechanical ahu and dropping it in. It'll be 10x more reliable, way more power/tq, and never have to worry about hurting the motor for overworking it.

Sorry for all the questions but I'm looking for reasons to keep working on the money bucket attached to my engine stand

How many miles on the engine?

Was it a stock VW head or aftermarket?

Do you have an EGT sensor/gauge and if so what is the highest temp you ever saw?

Have you ever overheated the engine?

436Kmi on engine before rebuild, had never been opened. Was a 91 ecodiesel motor. Didn't have an egt gauge as I'm familiar enough with tuning diesels and with the way I set the pump, the only time it would even smoke is under full throttle, low boost (smoking a tailgater out). So that tells me egt's were never in the danger zone.

Engine overheated once due to a coolant leak. Hence why I went through and rebuilt the whole motor at that time. Precups were still tight and only a hairline crack in a few of them around the hole. Every 6.9/7.3 IDI motor I've had apart had those so I wasn't worried. Ironically, the #1 is the one that didn't have any cracks.

[ORCoaster]

3K on a rebuild?   Oeeeveey.  That my friend just plan sucks.

[Whitbread]

3K on a rebuild?   Oeeeveey.  That my friend just plan sucks.

Yup, which is why I've had it with IDI's. I don't even like the one in my Arctic Cat, but it's been trouble free on 15psi of boost. DI's just have so much more torque.

Only in the last 200 miles did the 1.6 start acting funny, sounded like a lazy cylinder on a cold start. I assumed injectors and I was literally going to order some up as soon as I got home on friday. Needless to say, I never made it home under my own power. Glad I didn't piss away more money on that one  .

[wolf_walker]

Bad injector can kill any diesel. I know it blows and I feel for you, but there is nothing particularly wrong with IDI's.


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