TDI oil pump chain failure, here's what it look like...

[Sausage]

I bought a spare TDI engine el cheapo with oil pump chain failure last week, basically it will cost me nothing and i'll be in profit just selling the gearbox off it. I assumed it was toast and just got it for educational purposes and i wanted a spare head to port so no big deal if it is totally knackered, but i will repair it if the bearings are all ok, the turbo is shagged so not a good sign.

I spotted this 1st off:

That's a crack and 2 holes in the cover. 

Improvised crank locking tools.

Fookin tight!. tricky on my tod.

Pully off and cleaned up a bit.

Cover off and pic from underside.

The chain was smashed into pieces.

Crack shaft cog was distorted and cracked.

Spot the screw head....

Sump off.

These bits came out of the plastic baffle. (not the chain).

The balance shaft weight has smashed the tensioner body.

Edit: Correction, I think the only shaft with enough torque to cause this damage is the crank shaft, so it was chain bunching between the crank cog and the tensioner body that smashed the tensioner off downwards and ripped the tooth on the crank cog.

The screw heads are sheared right off and it is jammed in the cogs and the balance weight.

3 mounting screws still in the block.

That's it for now, i'll take the balance shaft off and then take main bearing and big end caps off and see what damage is done there another time.

Part 2:

Tensioner is supposed to look like this:

 

Edited March 28, 2016 by Sausage

[jon_273]

Well that's certainly seen better days! What do you think caused it?

[Sausage]

Well it's either a simple chain failure or else the tensioner failed followed shortly after by the chain. I'll clean up the tensioner bits and chain and have a closer look at them.

The pulsing of the 3 pot engine is not well suited to a chain drive on the balance shaft and as the oil pump is on there too then it can be catastrophic if the chain fails for whatever reason. The 4 pot tdi has smoother pulses but even so it is a poor design.

Mileage was about 170k on this engine btw. I'm just hoping they havent driven it home when it failed with the oil light on.

 

Edited March 28, 2016 by Sausage
fat fingers

[Sausage]

Well, the crank cog took a pounding all right it had spun on the crankshaft and turned brown with the heat. No wonder it wasn't round any more, it had to haul itself over the flat bits.

Crank should clean up, main bearings are shot, big ends are not the best either. So it's looking like it's for parts.

I'm investigating balance shaft delete for my own AMF engine now, this one was a 2008 BNV.

Edited March 30, 2016 by Sausage