Dropped valve? Now what?

[LOBOTAC]

Story goes....packed up the Jetta and headed out for a 200 mile drive to eastern washington for a weekend of fun in the sun.  All maintenance done.  Recent oil change, oil level good, coolant level topped off, recent air filter change.  Filled up the tank with a tank of fresh diesel, a bit of wax and some atf.  Made it across the pass with out a hiccup, across to the mighty columbia, crossed and headed up the long slow grade to the top of the other side.  Few miles up the hill, felt a shudder, pushed in the clutch, oil light on, coasted off of the interstate to a station at the lovely town of George.  Engine locked up.  Had a friend come with a trailer and towed it home.  Thought all along probably seized the pistons in the cylinder. Timing belt intact.   Once got it home put a socket on the crankshaft and turned it over freely almost a full turn until...clunk....definitely in the top end. 
Question....what do you guys think happened?  Where do I start?  I'm thinking pull the head???  Need some of your knowledge to help me get started on getting her back up and clickin and clackin down the road for another few hundred thousand. :-)

[burn_your_money]

I'd pull the valve cover and see if the head looks messed up from the top. If it does it's going to be expensive. If the head looks fine I'd rotate it and see that all the lifters are moving properly.

[TylerDurden]

I'd just pull the head.  The problem should be immediately visible. If not, I'd carefully turn the crank to see if it is obstructed.

[libbydiesel]

Probably a valve or pre-cup.  You're looking at a head, piston, rod and maybe a block... 

[8v-of-fury]

Time to drive on up to Canada and get yourself a 1.9L engine .

[LOBOTAC]

Thanks for the responses.  Going to tear in to it this afternoon.  Ill take pics and post them up later to keep all updated on what I find.

[CRSMP5]

the one that dropped a valve on me after putting a free unknown diesel in 8k prior ruined the head, piston/rod... i had it fixed for under 300 in parts.. day of work.. block never left car...

the one bbob purchased poked hole thru bore so 100% junk..

[LOBOTAC]

well, i am no longer a head virgin  .  Got the head removed and to my surprise found no damage to the head or pistons.  Rotated cam and all valves open and close as they should.  rotate crank and 3 of the pistons move up and down just as they should.  the other one......not moving....guess I pull the pan next? 

[theman53]

Got lucky..ish. When my #3 piston didn't move then I wrecked everything that touched the block. You at least have a good head.

[LOBOTAC]

So, am i right then to drop the pan?  Are you saying block is bad? 

[CRSMP5]

yea something broke.. pull pan,.. hope bad rod.. but assume bottom end..

[theman53]

yes you have to see what is going on.

[LOBOTAC]

got the pan off and found some peices as expected.  took some pics to share but having trouble getting them to post. any advice on getting the pics up here?

[TylerDurden]

I upload to Picasaweb (Google). Others use flikr, etc.

Then hotlink like so:

Code: [Select]

[img]https://lh6.googleusercontent.com/-htnflsyT7zs/UUp8ugsNNsI/AAAAAAAABFc/vbDJQxNwO_A/s800/hydraulicKSB1.jpg[/img](putting the image URL between the IMG tags, or using the Insert Image button)

[LOBOTAC]

Thanks for the help on getting the pics up. 
Here is what I found: 

Most of the pieces...





ouch...





You can see the piece missing at the bottom of cylinder...



Dont think elmers glues going to hold this back in place...


I have read that others have run blocks with chunks similar missing...Anxious to hear what you all think...I really would like to get this thing back on the road....im just cringing at the thought of filling up 2-3 times a week in my truck...Im cheap, thats why I drive or i guess did drive a vw diesel...help me get her back on the road with a minimum of costs and time.