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1.9l TD AAZ Timing belt tensioner pulley broke off
by
mortisetortoise
on 23 Jul, 2018 23:41
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Hello,
I took my van for a drive yesterday and the engine suddenly shut down. After being towed home and some trouble shooting, it looks like the timing belt tensioner pulley bolt sheared right off. Has anyone ever seen this happen? I cranked the engine a bunch of times trying to restart with the belt totally loose. Did I damage my valves?
Can anyone point me to part numbers and/or stores that sell the belt, tensioner pulley, and cover?
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#1
by
libbydiesel
on 24 Jul, 2018 00:31
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Yeah, unfortunately you definitely mashed valves. I haven't specifically seen that stud sheer off but stuff like that sometimes happens. Definitely pull the head. Look at the piston crowns for any valve impressions in the carbon. Replace any valves that made contact. When the head is off, check the combustion face of the head for cracks between the pre-chamber and exhaust valves.
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#2
by
mortisetortoise
on 24 Jul, 2018 00:42
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Thanks. I was afraid it could be bad. I will post updates here as I tear into it.
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#3
by
RunninWild
on 24 Jul, 2018 02:30
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Anyone know the best place to buy valves? I got one from tectonics tuning and I'm not sure i want to use it. The valve head is all rough and uneven and the base of the stem is also really rough. It looks almost like carbon buildup but its new... The face however is clean. Any issues?
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#4
by
Dakotakid
on 24 Jul, 2018 12:29
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Call the vendor and talk to them about it.
I bet it wasn't cheap.
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#5
by
RunninWild
on 24 Jul, 2018 15:50
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It was $20. I ordered a new one from partsplace last night.
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#6
by
ORCoaster
on 24 Jul, 2018 22:38
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But Techtonics Tuning should be refunding you some change as the part they provided clearly is not acceptable to you the customer.
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#7
by
RunninWild
on 25 Jul, 2018 00:15
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Ill email them some pics but cross border return shipping is usually more hassle then the refund. The valve seat looks fine just their finishing machining work is pretty horrible. Like i said the valve face is all ugly and the base of the valve stem looks like it has carbon buildup on it already lol. Id use it in a pinch but it doesnt give me much confidence in the quality of the part when it looks like crap.
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#8
by
Dakotakid
on 25 Jul, 2018 03:45
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many of the oem 1.6 hydro valves had a coating on the face for heat exchange. I'm trying to remember if any of the TRW's I have bought over the years had that or not.
I really don't like parts place now days. I think that the valve they sold you (I went to their site to look at the offering) should be boxed with a small bowl of rice and a couple fish heads due to the probable point of origin.
But, hey....we need MORE islands built in the sea down there.
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#9
by
libbydiesel
on 25 Jul, 2018 11:14
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Can anyone point me to part numbers and/or stores that sell the belt, tensioner pulley, and cover?
I'm curious why you are looking for the cover? Was your cover not in place?
You'll need to do a teardown before knowing what part numbers are needed. If a few valves are bent and lifters punched then you can likely get away with head gasket, valves, lifters, and a few other incidentals. If the pistons/rods are hammered beyond use, then it gets a lot more expensive. At that point, either a full rebuild or engine swap would be in order. If going for a replacement engine or full rebuild, you might consider going mTDI. If the block is usable, you can use it and the crank. I'm actually right now in the process of building an mTDI from an AAZ. Rods are dimensionally correct, but the TDI rods are stronger. The pistons need to be swapped. Also, needed are the head, injectors, and pump. I also prefer the added roller on the mk3 TDI's and so the pump bracket, timing covers, and backing plate need to be swapped to accommodate it.
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#10
by
mortisetortoise
on 27 Jul, 2018 00:22
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I listed the cover because when the pulley broke off it shot out of the bottom of the cover, shattering the lower part of it.
Update: Over the past few days I got all of the components off so that the head can be removed. I do not have the proper tool to remove the head bolts so I had to stop for the night and will search that out tomorrow.
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#11
by
mortisetortoise
on 29 Jul, 2018 13:31
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Update:
I got the head off and have removed the cam and lifters. i am waiting for a valve spring tool to get the valves out.
Upon initial inspection it does appear that there was some valve contact to all four pistons as evidenced by some minor witness marks.:
Cylinder 1:
Cylinder 2:
Cylinder 3:
Cylinder 4:
The other noticeable damage is to the cylinder 4 exhaust lifter. It looks like the valve stem broke through it:
Of note: I also found that one of three bolts holding the turbo on was missing and there was no gasket there, allowing exhaust gasses to leak out and likely reducing boost.
So my plan now is to get the valves out and check them all for being bent as well as checking the seats. Should I go ahead and replace them all as well as all of the lifters? Also, can someone recommend a good site to order parts?
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#12
by
libbydiesel
on 29 Jul, 2018 15:26
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None of your pics work. Try Imgur.
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#13
by
libbydiesel
on 29 Jul, 2018 15:28
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Absolutely most definitely replace any valves that contacted the pistons. It does not matter if they appear to be straight or not. Replace them. The head's have a tendency to fall of a couple/few thousand miles later.
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#14
by
mortisetortoise
on 29 Jul, 2018 17:24
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