OH NO! Valves, meet pistons

[hillfolk'r]

 ItsHydro lifters right? Check the lifters carefully,i had a similar situation happen to me,and the lifters all had these nice spider tracks coming from the center of the puck outwards,no lift no power
you could get lucky and thats your problem

Oh,btw i drove mine for 3 weeks with the lifters like that before i parked it and tore it down
yea its always fun when ya leave the wrench on the crank bolt.
i saw a dude hole a radiator on a big truck once doin that.
now i always make a joke and say take the wrench off the crank and look for all locks and tools sitting near moving parts

[alexgingles]

ouch.  When am I supposed to build this downpipe for ya?  I guess pretty soon 'eh?  If I were you, I would drill a port for an egt probe if you havent already.  I know some folks drill it with everything mounted.. I would take the manifold off and do it that way.  It's a lot easier to do this job with the engine out.  The Giles pump and your newly added lead foot will definitely raise your egt's. 

[92EcoDiesel Jetta]

I know a guy personally that left a rachet on a TDI and it bent a rod. Now a TDI rod is probably 1/2 the strength of our 1.6, but still I wouldn't want it to happen too often.

Good call on the IM bearings if they need replaced do that too.

Hmmm, why is a TDI rod 1/2 the strength of the 1.6? 

[theman53]

If you ever see one you will understand. My guess is they use 1/2 the forging to make them just by the looks of it.

[iheartbeets]

Hey Alex,
I still have all that 3" stainless tube.  About 24' of it.  I could drive it down to you but there's no one around that can bend the stuff (that I know of).  I did drill a hole in the manifold for the EGT probe.  Figured it's a good idea to keep an eye on.  Also got a boost gauge and mounted them both in the A pillar with this:

[alexgingles]

U might have to buy pre-bent u bends off eBay.  2 u bends required for the dp.  I think there is a place in Topeka that does mandrel bending.  They'll sell u bends too.  If you're interested I'll get their contact info for ya. 

[iheartbeets]

Ok. I think I want to get through this engine swap first. Kind of on a tight timeline. I got the longblock TD tore down. I'll be getting it all cleaned and prepped and all the new stuff swapped on it. I'll still give you the tube I promised though. I could bring it down this weekend.

[iheartbeets]

[audilvr]

if it makes you feel any better i put a na engine in my golf when i got it, drove it for 50k. pump failed spiking the rpm. replaced engine with td. made it 10 km on a test drive, crank broke. towed it to my dad's and didn't look at it for four months. now i have another td in it working ok, but i'm rebuilding a gtd engine so i know what i have next time.

[R.O.R-2.0]

if it makes you feel any better i put a na engine in my golf when i got it, drove it for 50k. pump failed spiking the rpm. replaced engine with td. made it 10 km on a test drive, crank broke. towed it to my dad's and didn't look at it for four months. now i have another td in it working ok, but i'm rebuilding a gtd engine so i know what i have next time.

the CRANK broke?!?!?!

pics or it never happened..

these cranks will crush rods all day and not even bend..

how on earth did you get one to BREAK?!

please tell me you took pics, or still have the engine, and are able to take pics?!

[slowcaddydan]

crank broke.

the CRANK broke?!?!?!

i'm willing to guess that the sprocket key gave way?

[slowcaddydan]

what's up with your alternator setup? is it an "ABF" setup?

[burn_your_money]

the CRANK broke?!?!?!

pics or it never happened..

Seriously. I want to see pics! Sorry about your luck though...

[Rock3tman]

It looks like the alternator/serpentine belt setup is from a non-a/c AFN...see photo attached of my setup

[audilvr]

if it makes you feel any better i put a na engine in my golf when i got it, drove it for 50k. pump failed spiking the rpm. replaced engine with td. made it 10 km on a test drive, crank broke. towed it to my dad's and didn't look at it for four months. now i have another td in it working ok, but i'm rebuilding a gtd engine so i know what i have next time.

the CRANK broke?!?!?!

pics or it never happened..

these cranks will crush rods all day and not even bend..

how on earth did you get one to BREAK?!

please tell me you took pics, or still have the engine, and are able to take pics?!

the keyway broke. i haven't taken it apart yet but the bottom pulley doesn't turn with the crank bolt.