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Engine Specific Info and Questions => IDI Engine => Topic started by: jimfoo on November 24, 2007, 08:08:49 pm
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Well, I finally made some progress on taking my engine apart. There was a lot I had to take off to get at it including my fenders. The inside of the exhaust and turbo outlet had lots of a sticky, thick almost tar like substance, probably from all the burning oil. Every tube and hose from where the vent hose hooks to the inlet hose for the turbo, all the way to the intake manifold had a lot of oil. I tried checking the timing, but I couldn't find my TDC mark on the front pulley, so I left it where the cam and pump are at TDC and will check the piston when I get the head off. I almost have it off, but there is a lot in the way. All I have left is the hose going to the water pump, and probably removing the head studs. The vaves on the VNT are also frozen, but I can see why if that sticky crap is on them. Tomorrow I will get the head off, take the turbo apart and take some pics.-
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Well, I guess I'll let the pictures do the talking... :evil:
(http://www.66rover.com/rover%20rebuild/CupTop.JPG)
(http://www.66rover.com/rover%20rebuild/CupBottom.JPG)
(http://www.66rover.com/rover%20rebuild/head.JPG)
(http://www.66rover.com/rover%20rebuild/2and3.JPG)
(http://www.66rover.com/rover%20rebuild/piston.JPG)
Theories? Caused by excessive oil in the cylinder, bending the aluminum under pressure, loosening the cup? 2 and 3 have a lot more cylinder wear though amazingly no big scratches. The ridges on 2 and 3 are much bigger compared to the almost imperceptible ones on 1 and 4. I'm thinking this is from when the intake hose to the turbo disintegrated, sucking in dirt and crud for who knows how long. It would make sense that most of it would go into 2 and 3. Also note the lack of cracks between the valves despite the high temps I would run at.
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Oh wow that is really unfortunate! Sorry to see this happen :(
How long and how much (what kind too) oil were you burning?
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Oil consumption increased suddenly, possibly caused by running empty from a sudden leak, the disintegration of my air hose and ingested crud, or both. I ran synthetic Rotella except for break in. It's only been running since June when I put bearings, rings and a new head on. Timing was still good, no slipped belt. It was getting everything covered with oil from the breather hose, so I hooked it back into the intake between the filter and turbo.
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"by running empty due to a sudden leak"
Do you mean that the oil ran out due to a sudden oil leak?
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The vanes were fine before this happened, so I imagine metal or goo are holding them. I should have said they can't be moved at all, not sticking.
So, how hard are oversized pistons to find? Also, since the block is good, what all would be needed to make it a TDI? Head, pistons, pump and injectors?
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Sorry to see the damage, Jim. yowch.
I noticed dieselvw.com includes sleeves with the items you mentioned above for a 1.6 tdi conversion, using the existing pump. (it looks like they haven't done one yet).
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Hmmm, could this be where the blowby was coming from?
(http://www.66rover.com/temp/rings.JPG)
Just a bit of wear on them. The thin ones in each set are from #3, and the wider normal looking ones are from #1. I think this kind of confirms my feeling about the dust and dirt that got in as being the cause of the majority or maybe all of the damage. I have no way to directly measure the bores, but the #1 ring in the #1 cyl had a .040" gap, and had greater than .075" gap in #3. I didn;t feel the need to find the actual gap as it was just plain huge.
Amazingly the bearings don't look very bad at all, but I had epoxied a magnet under the oil pickup, which had LOADS of ultra fine metal sticking to it. The #3 piston was very scored, and I actually had to pound it out as it was sticking enough that I couldn't pull it out by hand.
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Oh, and I didn't take the turbo apart yet, but it has loads of side to side play, and looks as though it's been wearing down it's sides on the intake scroll.
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Yikes that is ugly. Maybe the burning oil caused too much pressure in the precup and it eventually blew out.
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Bro, that ***ing sucks big time.