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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: Vincent Waldon on February 07, 2010, 08:49:04 pm

Title: Best example of diesel injector erosion I've seen yet
Post by: Vincent Waldon on February 07, 2010, 08:49:04 pm
Car has 340K km (210K miles) on the original injectors, according to the PO. Turbo went bang and bent some rods... occasioning me to pull the head.

First sign of trouble was the glow plug I pulled to do a compression test... I'll post a picture when I can find the little rotter...but it definitely had an eroded tip. Compression ended up being 100 psi... fine if you're a gasser but not great for a diesel. ;-)

Here's what I found when I pulled the head (piston's at its TDC BTW):

(http://i197.photobucket.com/albums/aa85/vwaldon/TDI%20Piston%20Details/Piston_closeup_800.jpg)

(http://i197.photobucket.com/albums/aa85/vwaldon/TDI%20Piston%20Details/head_800.jpg)

Once I got the piston out and cleaned up it looked like this:

(http://i197.photobucket.com/albums/aa85/vwaldon/TDI%20Piston%20Details/face_800.jpg)

(http://i197.photobucket.com/albums/aa85/vwaldon/TDI%20Piston%20Details/detailA_800.jpg)

(http://i197.photobucket.com/albums/aa85/vwaldon/TDI%20Piston%20Details/piston_profile_rescaled.jpg)

(http://i197.photobucket.com/albums/aa85/vwaldon/TDI%20Piston%20Details/profileA_800.jpg)

Moral of the story... like everything else, injectors have a service life... good idea to keep an eye on 'em. Piston erosion is a nasty business... overbore here we come.

This poor engine's had a hard life... this is the rod attached to that frazzled piston:

(http://i197.photobucket.com/albums/aa85/vwaldon/TDI%20Piston%20Details/bent_rod_D_800.jpg)

(http://i197.photobucket.com/albums/aa85/vwaldon/TDI%20Piston%20Details/bent_rod_A_800.jpg)
Title: Re: Best example of diesel injector erosion I've seen yet
Post by: Vincent Waldon on February 07, 2010, 09:22:19 pm
Yeah, this one's at the top of my personal collection for sure.

Haven't found anyone with a spare TDI hardline yet so have to send this set of injectors away to be pop-tested.. will ask Giles if he can take some video of what he finds on good ole #3 as he rebuilds 'em.

I'll leak test the head before I rebuild it and post up a couple pictures of the #3 exhaust valve to see if we can add any data to your theory.  Turbo actually has all its vanes...just a seal failure as far as I can tell.
Title: Re: Best example of diesel injector erosion I've seen yet
Post by: truckinwagen on February 07, 2010, 10:02:58 pm
the motor I just rebuilt had erosion from poor injection with perfect injectors.
turned out the heat shields were  installed upside down, causing the spray to drip.

the PO rebuilt it and ran it for 100 miles before giving up on it(couldn't figure out why it was running so poorly) and selling it to me for $100

-Owen
Title: Re: Best example of diesel injector erosion I've seen yet
Post by: Rabbit on Roids on February 08, 2010, 05:21:37 am
ive got a rod and piston similar to that, but its not burned, its smashed. it has a valve head sticking out of the crown too. an exhaust valve none the less.
Title: Re: Best example of diesel injector erosion I've seen yet
Post by: foxracer1 on February 08, 2010, 08:22:40 am
Quote from: Rabbit on Roids on February 08, 2010, 05:21:37 am
ive got a rod and piston similar to that, but its not burned, its smashed. it has a valve head sticking out of the crown too. an exhaust valve none the less.

Me too.

Thats interesting cause i saw somewhere reading about modding TDIs someone said that worn injectors will only cause poor fuel mileage. Ha i laughed to myself know they will erode a piston away easily for sure.

Nice pics and way to document it.
Title: Re: Best example of diesel injector erosion I've seen yet
Post by: diesel smoke on February 08, 2010, 06:39:29 pm
Ouch. So it was more than just a blown turbo. :'(

If you want a good set of used rods, I got a set. I was going to put em in the engine I'm building, but if I could get enough for em, I'm going to get a set of forged rods.  8) So make me an offer. I'll deliver to your front door. :)

If you are needing a hand, I'll be more than willing to come by and help. :)
Title: Re: Best example of diesel injector erosion I've seen yet
Post by: Kworth 2007 on February 09, 2010, 05:45:14 pm
Hi Vincent

WOW what a mess you have, I can't talk they (shop) still playing on the installment of the engine on my 96 1.9L that won't star in Mid December.  I asked for old parts to photo and add to the site.

Yes injector are the one main components to running a diesel.

the pistons I have not that bad.  4 new with bearings, head with new exhaust valves and seals installed

I hope by Friday  hmmm what friday?   I am learning lots for the forum  thanks for all the advise..

Cory Hanson

going broke, driving a V8 pickup to work daily. 
Title: Re: Best example of diesel injector erosion I've seen yet
Post by: Vincent Waldon on March 06, 2010, 08:07:50 pm
Lookie what Myke sent me:

(http://i197.photobucket.com/albums/aa85/vwaldon/Blue%20TDI%20rebuild/newpistons.jpg)

I just love the smell of machining oil in the morning.  It smells like..... VICTORY!! ;D
 
Title: Re: Best example of diesel injector erosion I've seen yet
Post by: Kworth 2007 on March 06, 2010, 09:10:37 pm
Vincent Hi

I am trying to upload the damaged photos from the 96 Jetta  engine

darn Vista system PC

I agree the smell of Oil mmm

I did not know that my Jetta speedo would go back to ZERO on 300,001 km

I have a new car for sure now with the engine & speedo

Cory Saskatoon,SK 

compact flatdeck trucking business
 now put a hitch on the car  looking out western car here I come.