Noisy lifter! was "Got Problems! Lost a prechamber inse - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Noisy lifter! was "Got Problems! Lost a prechamber inse by Patrick on 22 Jul, 2005 19:01
• Wife's 1.6 TD (hydraulic lifters)Jetta came home with a miss. Cracked injector lines and determined that the problem was on the #1 cylinder. Pulled the lines (and #4 injector came loose), did a compression check on #1 and got 150 lbs. checked #4 since it was already loose and got 410 lbs.
  
  Obviously the head is coming off.  I'll check the other two cylinders before it does.  What exactly do I need for the head bolts? Want to get the head off tomorrow because sunday is already booked. Can I pull turbo, exhaust maniflod etc. with the head as one unit from this car? probably a lot easier to get bolts out afterwords!
  
  I'm guessing a bad valve, but who knows until I get in there. Fortunately I have two weeks booked off work starting monday, supposed to be gone the 2nd week and here the first. WAS going to do some work on my truck, but that's obviously going to have to wait. I do have a pretty much complete parts motor that I pulled from this car because of poor compression.  Maybe a good head on the other motor? I'll see.
  
  HELP!!!
• #1 by srivett on 22 Jul, 2005 23:43
• I'd leave on as much as possible for the inspection.  If you can't get the top end off in one piece you can reinstall the old head bolts to aid in removal of the turbo stuff and manifolds.
  
  Steve
• #2 by Patrick on 23 Jul, 2005 03:06
• What driver do I need? If I walk in and buy a triple square set, am I going to get the one I need?
  
  What's chances that this is a head problem? Is a broken ring more likely?
• #3 by Patrick on 23 Jul, 2005 07:59
• Pulled the head, number one cylinder is hammered, and the insert is gone.  :shock: Head is also hammered, small cracks between the valves on a couple of other cylinders. Debating pulling apart a high mileage parts engine I have and making one out of the two. If the other head is okay, maybe a piston and a set of rings will have it up and running. Have to see how the other one looks. I may be shopping for an engine............... :cry:
• #4 by QuickTD on 23 Jul, 2005 08:14
• The cracks between the valves can be ignored. They don't usually hurt anything. I think they form as soon as you start the engine. Don't worry if the "new" head has them. There is some danger of a valve seat loosening if they get too wide but they would need to be nearly an inch deep to hit coolant or oil.
• #5 by Patrick on 23 Jul, 2005 08:39
• Thanks, I knew the cracks weren't a big issue. The head is hammered pretty bad, as is the piston. there's a little bit of a wear mark on the top of the block like the insert was moving for a while, but I don't think it's enough to be a problem.
  
  I thought the turbo sounded a little strange, and after seeing the engine I'm assuming the pieces went out the turbo and buggered it too, been there done that with a burnt valve on an 855 cummins a bunch of years ago.
  Guess after lunch I'll tear into engine # 2....................... :roll:
  
  Pulled the piston out, there's a mark in the cylinder that (I think!) will be okay with a little hone job. Haven't got to engine #2 yet, and have to move a couple of horses tomorrow so won't get to it until later on. Anyone got a GOOD 1.6 or 1.9 to get rid of?
• #6 by chrissev on 24 Jul, 2005 18:26
• before you put it all back together, check the connecting rod carefully.  I would bet money it is bent.  If you leave it bent you can expect to see it crashing through the side of your block sometime soon.
• #7 by Patrick on 25 Jul, 2005 03:11
• Not even going to check it, scavenging a complete rod/piston assembly from the engine the head is coming off for just that reason. Good call though!
  Cylinder bore is a little marked up, just going to give it a light hone and rering. Anyone thiink a bad injector could have caused this due to an overheat situation? Or was it just a part failure?
• #8 by Patrick on 27 Jul, 2005 09:33
• UPDATE!!!!
  Engine 1 (lost insert) was overbored, so pistons from engine 2 (original) won't fit.
  
   Engine 2 needs work, prechamber inserts are showing cracks, ring lands are bad enough I figure the engine should be bored, new pistons, etc. More money than I want to spend on this car.
  
  Wreckers all say nothing available, no 1.9's of any description, only found 1 high mileage NA 1.6 for $550.
  
  TRIAD to the rescue!!  Found a complete running TD Jetta w/5speed, parked for at least a year, took ten minutes to get it fired, no blue smoke, some black. Seller even loaned me his tow bar to take it home.
  $400!!!
  Anyone need an AGS tranny with the big backup switch? :lol: This thing could get pretty cheap if I use or sell a few more parts.
  Pulled the new engine (#3?) this morning. (Great way to spend my week off eh?) Looks like a different wastegate regulator. Kind of finned on the mount, and a very smalll threaded piece sticking out with a nut on it. Adjustable wastegate??
  
  Checking the timing belt this afternoon, unless it looks brand new it's coming out.  Should have the other car apart this afternoon or tonight, and might have it running again tomorrow (I hope!!)
• #9 by Josh on 27 Jul, 2005 18:13
• Patrick,
  
    I assume you found that the triple-square set contained the size you needed, yes?  
  
    You work quickly, which is impressive!  Are you involved in a mechanical profession?  I work by myself and find it difficult to muster enough muscle many times to break loose some bolts.  
  
    This TRIAD you mention; a website, local paper, or service?  
  
    Thanks,
  
      -Josh
• #10 by Patrick on 27 Jul, 2005 18:58
• Yup, found the tool I needed at a local auto supply store. As for breaking them loose, get a bigger Johnson bar! Thanks for the complement on the speed! I've got this week off work (and next week) and was supposed to be working on a few things on my truck when the wife's car decided to calf. The push is on because I've got things booked for next week that are already paid for, and because I want my car back, my wife's driving it to work (92 Jetta 1.9TD).
  
  Took about 3 hours to have engine #3 (with tranny still attatched) sitting on the floor, and no I'm not really in a mechanical profession, but I've been fixing my own stuff for a long time. Got serious about fixing diesels a lot of years ago, had a Kenworth with a lot of miles on it. Once replaced a piston in a truckstop parking lot in Porter Indiana, had to borrow the truckstop's truck to go to Chicago Cummins for a piston kit! Only tool I didn't have in the truck was a torque wrench. Not trucking anymore, work for the municipal government here.
  
  The TRIAD is a local buy/sell/trade magazine that you can advertize in for free, people sell just about everything in it.
  
  Question: Engine #3 has a K24, engine #1 and #2 had T3's. THe wastgate on the "new" engine looks adjustable. Can anyone shed a little light? Newer, older, what's the deal? Also found a tag on this thing that says it's a factory rebuild.
• #11 by Patrick on 29 Jul, 2005 15:35
• Update: Car is running.Still need to do a little work on the exhaust sometime soon, going for a test drive after supper. Seems to be idling a little slow for my tastes, and the low speed screw is siezed in the pump body. Soaking it with a good lube, may have to heat it to free it up. Eliminated a lot of non working air conditioning parts, built an alternator bracket that's a lot easier to adjust than the one in the other non air conditioned 92 that I have. Used parts from the 92, an adjuster assembly from a Fox, and a couple of pieces of flat stock. Had to change the pulley on the alternator too. Been a busy week!
• #12 by Patrick on 31 Jul, 2005 03:44
• Idle speed seems good now that engine has run a bit. Engine has more "zip" than the one that came out, fueled a little higher maybe? I like! had an issue with an oil pressure sending unit, fixed by swapping in the one from the other engine.
  Engine seems a little noisier, almost like a lifter out of adjustment,, but it's a hydraulic head engine and the cam looked good when I put a belt on . Any ideas?