Salvage 1.9 - a.k.a. Ooooh, that'll leave a mark!!!!

[Mikeyworks]

Well,

I got into pulling my salvage 1.9 apart last night and trying to figure out why the #1 piston hit the valves.  

First of all, I got the crank pulley off. I had originally thought that this was an early 1.9 with the Woodruff key in the crank that often sheared off. I got it off to find this:



Honestly, not what I was expecting.  Does this place this engine as being after a certain mfr. date?


Here's some more pics of the damage to the engine:

The head....
#1 is toast
#4 looks like it was leaking a lot of coolant!!!!



Here's an up-close shot of piston #1



Here's the head side of #1
- you can see pieces of the valve imbedded in the head, they won't come out.
- you can see one of the valve heads wedged in there tight, also will not move
- there's a broken piece of the head that's just crushed out of the way



...oh well, I think this head is a total loss!!!

Here's a shot of the oil pump pulley....oddly enough it has some strange damage to it...



...any thougths on what would cause that?

Here's a profile shot of the pulley.
You can see at the top of the pulley, it's slightly out of round, in the same pplace as the damage shown above.




Any wisdom or insight will be appreciated.

I am hoping to rebuild this block into a 1.9TD to put into the Caddy by mid-summer (budget pending).  :lol:



-Mikey  

[86AAZ]

That oil pump pulley looks like the pump might have seized up and the timing belt kept going!  I've never heard of that, but it's an idea, I guess.
Good luck!

[chrissev]

I agree.  Looks like the intermediate shaft for some reason stopped turning and the friction of the timing belt melted that pulley.  Did the timing belt break or slip a tooth?  Nice cracked piston in #1 cylinder.  Have you had a look at the connecting rod to see if it is bent?  Might be a good idea to replace it anyway, so you don't end up throwing it out through the side of your freshly rebuilt engine at a later date.  The damage to that cylinder head is just unbelievable.  I bet the engine was revving pretty good when the timing belt broke.

[Mikeyworks]

Like I said earlier, I bought this as a dead engine so I only know what happened by the PO telling me what he knew.

Apparently this 1.9 was in his Vanagon and was doing great at about 40 mph. he was about to shift gears (guess in high in the RPM's) and heard a loud noise followed by the sudden stopping of the engine. It stalled out on him pretty fast.

I think the intermediate shaft probably locked up (though it's free moving right now) and burned up the pulley, this in result stretched the belt which then jumped a tooth and threw the cam timing off. With the cam timing off, it just went to town eating up piston #1.

I am going to pull and replace at least piston #1....should I replace them all?

I am looking forward to pulling the pistons this weekend to see what that con-rod looks like!!!!!   :twisted:

Mikey

[lord_verminaard]

Holy crap.  Yeah, i'd say that head is pretty much F'ed in the A.   :shock:

If someone was REALLY good at aluminum welding, they may be able to fix it by doing some surgery and filling in the big gaps, then CC'ing the head to make all things equal.  But unless you were good pals with that person, it would probably be more cost-effective to find a replacement.  

You might be able to get away with only replacing one piston.  Buy a new one, and take the new one plus the other three to a machine shop, and they can balance them all out for you, and unless there was unseen damage to the others, it would be fine.  Remember though, if the cylinder of #1 took any damage, you would need to bore it out, and then you'd need 4 shiny new pistons.  

Really strange that the intermediate shaft just "stopped".  Especially if it turns now.  It almost looks like someone whacked the side of it with a big hammer!

It might be dead now, but we can rebuild it, we have the technology....  

And it aught to run like a champ afterward.  

Good luck with it-

Brendan
84 Scirocco 8v
00 Camaro L36 M49

-Edit-
Looks like those 1.9 IDI's have some monster valves in them!  They must flow really well....

[fatmobile]

Does that new style timing gear have a part # on it?

[QuickTD]

The part number for the new "TDI style" crank pulley is 028105263D. This is the pulley I generally install when I repair a AAZ crank. I guess this gear is what is coming from the factory now. My car is a 97 and it still has the old style. It's safe to assume that this engine is either later than 97 or has had the crank repaired at some point.

[Mikeyworks]

Some information I neglected to mention.

The engine has about 2000 miles on it...yes, that is right, 2,000.  The engine came from Overland in PA/MD a couple years ago, was installed in the Vanagon I pulled it from. It was a weekend driver, purchased by the PO (that I got the engine from), who then drove it
(hoping to make it a daily driver) for nearly 1 month...it then keeled over!!!

I am going to pull the pistons this weekend.  I hope there is no damage to cyl #1.

I also want to pull the engine from my Caddy this weekend and start disassembling that.

My hope right now is to replace that damaged piston (getting them balanced of course) and maybe just put my 1.6TD head on there. I can play around with that and port and polish it to enhance the head and get it closer to 1.9 specs (will never really get there) and maybe save up the cash to get a replacement 1.9 head.  I have been watching the 1.9 heads on eBay and they usually go for way too much!!!!

Do you guys think I should re-ring all the pistons when I replace #1 or just the one?

Thanks,
Mikey

[Mikeyworks]

and just out of curiosity....can anyone confirm whether this is a mechanical or hydraulic head?



(I think I know the answer but I am not positive)

Thanks,
Mikey

[lord_verminaard]

 I have been watching the 1.9 heads on eBay and they usually go for way too much!!!!

Do you guys think I should re-ring all the pistons when I replace #1 or just the one?

Thanks,
Mikey

It seems like Vanamania is the only one out there that has stuff for 1.9's on Ebay.  I honestly dont know how they sell anything with reserves of $1,000 or more on used, unrebuilt engines and $900 heads.  That is WAY WAY WAY more than they are worth.  A lot of peoples cars arent worth that much!!!

I'd probably re-ring them all.  Even if it's 2000 miles old, at least you'd know they are on there and wouldnt have to wonder.  There's something to be said about peace of mind.  

and just out of curiosity....can anyone confirm whether this is a mechanical or hydraulic head?

All 1.9's were Hydro.

Brendan
84 Scirocco 8v
00 Camaro L36 M49

[QuickTD]

If it's a 1.9, it's hydraulic, they aren't available any other way. The 2 oil drainback bulges in the front of the head also give it away. And, since you have the valve cover off, the most obvious clue will be the lack of adjustment shims in the tops of the lifters.