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TDI has just gone bang - advice needed


RXStdi
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Thanks - looks like I will be needing one as I stripped the head down today and the damage is worse than I expected.   Five of the tappets are badly damaged and although the camshaft looks OK I do not think I want to use it after it has taken such a hammering.

I have attached a couple of photos of the damage - all caused by one broken stud!

 

IMG_0472.JPG

IMG_0474.JPG

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9 minutes ago, mk2 said:

now, i wonder what has happened to all the bits of metal... and what do they have to go through before they get into the oil filter....?

=engine swap

Won't they just end up in the sump....? Eventually.....

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Interesting mix of opinions but after a fair bit of thought I have decided to have a go at fixing it - guess I must be a chancer too!

I have had a close look at the top of the pistons and there is only slight marking (which is surprising considering the state of the tappets) and the engine turns over freely.   Although the tappets look bad in the photos I do not think that many damaged bits have actually come off and agree with Rich and Skezza that any bits should just end up in the sump so will take that off and check (obviously will change oil and filter).

The cost of a set of new tappets and valves added up to quite a bit so I have ordered a secondhand head off EBay and also head gasket (TPS) and timing belt kit so hope to make a start next week - may well regret this decision but will keep you informed so that if anyone else is unlucky enough to have this happen it may help.

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carefully inspect your replacement head for signs of oil starvation (cam lobes) as the I would guess the usual reason for a spare head is a duff bottom end from oil pump chain failure, especially if it is off a non amf engine.

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if you are looting parts from them I have a spare spare (yes double) amf head which suffered a belt failure.

it's yours if you want it for postage?

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Sorry it has taken a while to respond - have been busy sourcing info and parts and stripping down the old head.

Thanks for the offer of the head, I may well need some bits but should know better by this time next week.  I could not find a complete secondhand head as all the breakers remove injectors - bit of a pain as getting the ones out of my old head proved really difficult after being there for 125k and 17 years and it means I have had to buy new seals as well.

Will probably not have time do anything more till the weekend.

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  • 1 month later...

Thought I should attempt an update on repairs to the Lupo after it went bang.  I intended to take photos but always seemed to be trying to finish off whatever bit I was working on and not wanting to waste time cleaning hands to use a camera.

 

When I stripped down the head all the valves were bent and all except one tappet were damaged so I bought a secondhand head on Ebay.   This came without injectors and removing the injectors from the damaged head proved to be more difficult than the manual indicated (they had been in position for 122k and 17 years).   I then had to buy new injectors seals before fitting them to the replacement head and setting the adjustment - this all took quite a while.

I bought a new VW head gasket but the head bolts and cambelt kit came from ECP to save some cash.   The cambelt kit is a Dayco one because I needed the hydraulic damper as well and VW charge over £100 just for this item - not sure about the Dayco kit as neither the tensioner or cambelt look to be such good quality as the original VW parts but much cheaper.

Costs:

Second hand head £100

Head gasket £40

Head bolts  £20

Cambelt kit £125 (needed hydraulic damper so expensive)

Injector seals and bolts £22

 

Total cost was over £300 and this was cutting a few corners by re-using gaskets etc and also the fact that I already had all the tools that I needed.   I have now had the car running again and have changed the oil and coolant and at least it seems to be OK - time will tell!

I initially thought the failure was due to the tensioner stud breaking and that the damage to the hydraulic damper was caused by the assembly dropping but maybe it was the other way around and the damper failed first?

 

All in all an expensive problem and a warning that when cambelts are changed then all the other components should be replaced at the same time.

 

Thanks to all who gave advice.

 

 

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7 hours ago, RXStdi said:

Thought I should attempt an update on repairs to the Lupo after it went bang.  I intended to take photos but always seemed to be trying to finish off whatever bit I was working on and not wanting to waste time cleaning hands to use a camera.

 

When I stripped down the head all the valves were bent and all except one tappet were damaged so I bought a secondhand head on Ebay.   This came without injectors and removing the injectors from the damaged head proved to be more difficult than the manual indicated (they had been in position for 122k and 17 years).   I then had to buy new injectors seals before fitting them to the replacement head and setting the adjustment - this all took quite a while.

I bought a new VW head gasket but the head bolts and cambelt kit came from ECP to save some cash.   The cambelt kit is a Dayco one because I needed the hydraulic damper as well and VW charge over £100 just for this item - not sure about the Dayco kit as neither the tensioner or cambelt look to be such good quality as the original VW parts but much cheaper.

Costs:

Second hand head £100

Head gasket £40

Head bolts  £20

Cambelt kit £125 (needed hydraulic damper so expensive)

Injector seals and bolts £22

 

Total cost was over £300 and this was cutting a few corners by re-using gaskets etc and also the fact that I already had all the tools that I needed.   I have now had the car running again and have changed the oil and coolant and at least it seems to be OK - time will tell!

I initially thought the failure was due to the tensioner stud breaking and that the damage to the hydraulic damper was caused by the assembly dropping but maybe it was the other way around and the damper failed first?

 

All in all an expensive problem and a warning that when cambelts are changed then all the other components should be replaced at the same time.

 

Thanks to all who gave advice.

 

 

that was expensive. hopefully all sorted for another 100k miles! :)

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