HELP - Sick V6 TDi

[S2central.net]

I can't afford to do it any other way. That and there isnt anyone i would trust enough to take it on. I did need a bit of help on those manifolds though - fatigue and hangover saw to that. It's costing me three days extra holiday. Some holiday. Cams not here yet so thats annoying. Was hoping to build heads tonight.

[sdk778]

Hats off to you sir, I've tackled heads off on these engines twice now, in an equipped and heated workshop, on a two poster, and it was still an utter ball ache, so mucho credit to the driveway job you are undertaking.

Again, at least you are saving some coin, just think of that as each problem bites you on the ****, you will soon forget the skinned knuckles and rain sodden **** when you fire it back up and grin, knowing you beat it.

[S2central.net]

I'm so bored cleaning valves now. Even after a treatment of carbon remover I need to scrape off the heaviest deposits. Tis odd as some valves are much dirtier than others.

Now I am wondering if I should lap the valves into their seats but I think I am being too fussy with that.

Today's voyage of discovery was that swarfega heavy duty hand wipes are superb for lifting greasy mess of the head surfaces and piston tops in the block. Much less messier than chemical sprays. A sharp blade is needed to lift the odd residue of gasket.

Cams didn't arrive today so thats a bummer. On the plus side I did get my EGR blank plate today so that will put an end to the devils vomit generated by that stupid invention.

[S2central.net]

Pics of shiny valves just uploaded. There was much rejoicing. Hope to get block faces cleaned and prepped tomorrow in daylight before cam gear arrives. Cannot rush this patient off the ward now !

[s2_wot]

Pics of shiny valves just uploaded. There was much rejoicing. Hope to get block faces cleaned and prepped tomorrow in daylight before cam gear arrives. Cannot rush this patient off the ward now !

Inspiring work Paul,
were the boost hoses damaged before or during surgery? It'll be like a new car. Love "the toxic twins" shot. I admire the foresight to pull the 2 heads and sort them out proper

[S2central.net]

Just realised that I forgot to order a new crankcase filter. Seems to be a common cause of oil leaks on the V6. I get some seepage at the injector seals in the cam covers. Worse so on one side actually. No real sludge to speak of in the oil. Seems silly to leave the breather alone when everything else is outta the way.

[S2central.net]

Forgot to say the boost hose damage was before my time. Someone must have snagged the maf hose with the clip whilst the other hose just had the outer shield worn and split. The bacofoil looks shyte but is more robust.

[S2central.net]

Here is an interesting development. I got all the cams and lifters today. I was looking thru box of removed parts to visually check the lifters were correct. I couldn't help but notice how thin the oil felt around them. I remember during dismantling that the oil wasn't as gloopy as you would expect.

Many of the old lifters gave no resistance whatsoever when pressed by hand. Sure some oil has drained off them in 4 days but something doesnt feel right.

I called a professional round for a 2nd opinion and he agreed with my view. Its almost like diesel has mixed with oil. I used a fully synthetic proper VAG approved oil at the last service and have always done so at 10k intervals.

Makes me wonder if an oil pressure or contamation caused the oil to break down which then led to camshaft and lifter wear which might explain why there was no noticeable degradation in the engine until it just died last week.

I will have to check the oil valves in the head for blockage and make sure the head is getting plenty of oil during some cold cranks after it is rebuilt. Otherwise these cams will die very quickly.

The other fun is that we tested glow plugs on the bench with a jumper pack and all 6 are dead. That explains the fun sometimes starting on a frosty morning. Suppose that'll be another 100 quid then. Fook !

Anybody any ideas on the oil issue ?

[S2central.net]

Anybody got a clue what sort of oil pressure to expect on cold cranking ?

I hate how the allroad doesn't tell you oil pressure - you are totally reliant on pressure switch into autocheck / DIS gizmo.

[GT500]

Got a PD golf to do with leaking injectors. 8 litres of oily diesel came out at service. Not had it on a V6 though. Whats your oil level like?

[newsh]

Whoa, just catching up with this Paul, what a mission! I was fancying one of these too

[S2central.net]

@GT500 - can you please explain more about that failure of the injectors ?

Is the injector itself lubricated by engine oil such that some internal failure causes diesel to mix with oil ?

Do I need to extract all the injectors and have them professionally tested ?

Number 6 has been visibly burning much differently to other cyls... like a glaze on the piston top which is odd. I just put that down to poor combusition because valve timing is off.

Starting to wonder if I should just dig deep and renew the oil pump for the avoidance of doubt, but then I will see how well its pumping up to the heads on a cold crank.

Oil level was fine when checked recently. Gonna remove oil tomorrow and check its condition - thank goodness I hadn't just doneit day 1 and dumped it without checking.

All of a sudden I love my S2 a lil bit more during this episode !

[diesel des]

Paul, get the injectors tested. There is someone in bangor does common rail injector tests. They leak into the cylinder and the fuel gets into the oil, then wearing game etc... are those v6 common rail or rotary pump

[S2central.net]

Its the high pressure radial pump on these. Will look for that local place to see about tests. I gather special tools are required to remove the injectors from the head. Oh my heart is broke with this. Wait til 'er indoors hears the car won't be ready at the weekend

[s2driveruk]

...can....of....worms....what a nightmare