VWDiesel.net The IDI, TDI, and mTDI source.

General Information => Troubleshooting => Topic started by: dillenger1 on December 20, 2007, 05:40:49 pm

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on December 20, 2007, 05:40:49 pm

So ive got my engine  dissassembled,and i was inspecting my head up close.I had it under some good light and noticed a funny mark.First i though it was a casting flaw,but then realized that ive got cracks on inj. bosses 1 and 3 ,almost alll the way down to the glow plug.Its cracked all the way through to the thread on the other side.Im furius,but better to find it now.WE started it up before tear down ,and it was running horrible like it was missing.When it came time to take out the injectors i let them soak in pb blaster for a while then i hit them with an impact gun!(bad?)I was wondering if i could have done this,with the impact gun?

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on December 20, 2007, 06:49:49 pm

help!

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on December 20, 2007, 06:51:06 pm

Am i screwed ? Is it beyond repair?Its a  hydr. head.Can it be welded succesfully?

Title: cracked injector bosses!!!!!!
Post by: Quantum TD on December 20, 2007, 08:00:59 pm

If it can be welded, it can be repaired. It's just a matter of how much you're willing to spend on repairing the head, and if you can find a shop willing to take on the job.

In the end, it might be cheaper to find a good core (they run about $75-175), and just rebuild it. Any used 1.6 head is bound to need new guides, seals, and exhaust valves: even if none are bent. The diesel exhaust pits the stems after about 150k.

Title: cracked injector bosses!!!!!!
Post by: jtanguay on December 20, 2007, 08:43:23 pm

you'd want to remove the injectors while the head is hot.  that way there is a far less chance of it cracking.  take some pics of the crack if you can.  stuff like that sucks :(

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on December 21, 2007, 03:12:49 am

im gonna try to take the pics ,but i dont knoe my dig camera isnt that good

Title: cracked injector bosses!!!!!!
Post by: Doug on December 21, 2007, 04:35:37 am

I have been running a head that has a welded injection boss for several years with no problems. It is definitely worth the effort to repair especially if you have sunk the money into it to renew the head. A good welder will have no problem as the base casting material is quite dense. Then you have to chase the threads. A machine shop could easily do that or you could probably do it yourself with a home made tool from an old injector body with some slots cut through the threads.

Title: cracked injector bosses!!!!!!
Post by: jimfoo on December 21, 2007, 06:25:36 am

And don't forget to put anti-seize on them before putting them back in.

Title: cracked injector bosses!!!!!!
Post by: Op-Ivy on December 21, 2007, 11:36:25 am

Thanks for the tip Andrew! Good logic. My Injectors have never been out... Next spring they are going to get a rebuild I thinks. :)

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on December 21, 2007, 04:33:31 pm

Thanks guys,so do you think its worth tryin to save the hydro. head?I havent put a penny into it yet,but im also planning to boost,and its made for na.What are the real differrences between the heads(na and td)

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on December 22, 2007, 05:00:49 am

No nothing like that.,just on the bosses inside 3/4 ways down the thread,outside also ,looks like a casting flaw.Sort of like its gonna flake off.they run down almost to the glow plugs.I was wondering if this could cause compression issues afterwards with the nozzles/spray pattern

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on December 27, 2007, 04:21:23 am

http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel064.jpg

heres the injector boss ,took me awhile to learn to post pics,sorry :P

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on January 01, 2008, 03:37:08 pm

has anyone ever had luck with the sodering.I saw an ad for some product tc-500 or something.It was an aluminum type soldering rods.they said it could repair a cracked head if it was done properly?

Title: cracked injector bosses!!!!!!
Post by: jimfoo on January 01, 2008, 05:12:19 pm

You need to gt it properly welded.

Title: cracked injector bosses!!!!!!
Post by: dillenger1 on January 02, 2008, 06:04:01 pm

I have those cracks on two of the bosses.I also have cracks between the valves on three out of four cylinders.Now its a hydro head,would it be stupid to take "solid" for trade?Im still thinking i caused the damage during the strip,but i had no way of know this would happen,well,i guess its a learning experience. :roll: