HELP - Sick V6 TDi

[Pirvu Eugen]

Diesel fuel in oil at that engine can be caused by the fuel unburned in those cylinders affected by the cams wear and cold startups with broken glow plugs. Has to do with unburned fuel. These injectors are not so prone to leak as the PD injectors or Comon rail ones. My opinion is to check the injectors for opening pressure and spray patern.
Usualy..these injectors are working for 400k km.
All the best!
Goodluck!

[S2central.net]

Well the other theory is that with the mad cam wear and the back pumping of the inlet valves - they would also have had diesel spraying up past the VSOS and into the valvetrain. The VSOS would not be able to stop that.

Have only had an hour or two on it today. Have one head ready for camshafts. More photo uploaded to the gallery.

Got 6 new glow plugs for 70 all in so that wasn't so bad.

Will drain the oil tomorrow... If the oil is heavily contaminated then it's gonna be a new oil pump. I am holding fire on getting the injectors out for tests at the moment. Pending state of the oil.

Reckon I will lift off the fuel pump to give me lots of access to the dopey breather thing in the middle of the V. I can also examine the condition of oil in the upper gallery too.

Oh the joys.

[s2_wot]

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

Could you imagine the main dealers face if you brought this lot into him and standing there waiting for you to part with £2k for all the work you've done

[S2central.net]

Psg side head built up and lovely tonight. Good progress on drv side but I need sleep.

More photos uploaded annotated with info

[S2central.net]

Quick update before I top myself. Potential last post of a dying man :-)

Bothe heads built up lovely and aligned.

Both heads fitted today and battles won with worst manifolds.

Water pipes and such refitted ok.

I renewed the crank breather and deleted the EGR on Saturday

Timed it all up then set tension on the primary belt. Torques up the can pulleys and looking real good

Then I removed the lock pin and plates for a hand crank

I get just over one and half turn and the thing locks up. One of the new lifters must be seized or some ****ing thing. I have been out there since 9am today and right now is a very low point.

Now I have to think about getting the energy to remove the belt again... Suppose I can set the crank a quarter turn past TDC on 3&5 so that all cams should be free to turn. Then I can find which head has the problem. I am driven demented by this thing. Just more shyte that I don't need. It'll be cams off in situ then to zoom in further on the problem.

Is there way to spot a bad lifter on the bench ?

[Pirvu Eugen]

Paul, you let the lifters in place..after installing the cams..for few hours before tring to turn the engine? They need to let the unnecessary oil out before the engine can be turned. Or...are you sure the timing is corect? And 3 thing..sorry..but you sure you installed the intermediate pieces..between the valve and tapet corect?
Hope is only the timing out, or the tapets didint have enough time to loose some oil.
Goodluck!

[diesel des]

Yea Paul I have had this issue with a over pumped tappet. Also can give no compression problems. Leave it just before the engine locks overnight and look in the morning.

[S2central.net]

Thanks lads but was something really silly. I had a friend come down just earlier for fresh eyes. He has built many more engines of different types and he too was really scratching his head after checking the timing and agreeing with me it is impossible to get cams mixed up. Both heads had sat for hours by the way as I know about the clearance thing with lifters.

He wad thinking as there were non audi cams that the alignment marks might be 180 degrees out so we set about checking from 1st principles again. Took out glowplug on #3 to confirm it was TDC when pin was engaged - he was thinking cams might be set for TDC on #5.

Anyway we took off the main belt in the rain and set the crank so it was TDC for nobody. Set about turning the right bank with cam pulley and all was fine. Then we tried same of left bank and it locked up solid so then he is ahreeing with me there is a valve or lifter seized somehow.

THEN ... This one is for the books... Then he notice the three extra bolts in the left pulley that hold the pulley for the fuel pump. I had left them screwed in there so as to keep them safe. One of them was screwed in too far and interfering with one of bolts for the rear timing cover. Oh how we ****ing laughed. If I had just ploughed on building to next stage before hand cranking I would have been none the wiser - it was perfect all along. Beer is being drunk tonight for sure.

[newsh]

Thank Flip for that!

[s2driveruk]

well done glad it was nothing major

[S2central.net]

Just loaded more pics to the gallery. Will add more tomorrow.

Those heads go on nicely with manifolds fitted in advance but it's tricky keeping the gasket to next part of exhaust in place and access to those bolts is a right booger. I have the scars to prove it but with fresh nuts and bolts I found it was ok to tighten with lil stubby spanners.

[Pirvu Eugen]

Uff! Glad is nothing major! Well done!

[Fat Audi 80]

Keep going Paul, nearly there....

[S2central.net]

Yeah only another 4-6 hrs build up if it stays dry enough for me. Reckon on an hour of that to bleed the dang fuel system.

[S2central.net]

Got another ~2hrs today while dodging the rain. Retimed again from scratch without those annoying pulley bolts and all is well. Changed the oring on dipstik - that's a faff.

Then refitted the roller tray / viscous fan bracket - took a few good wiggles to line it up.

Fuel belt and associated timing for that is next. Then it's the crank damper and ribbed belt before refitting air pipes and fuel lines.

I'll do a cold crank without fuel just to pump some fresh oil up top.

Reckon it's another 3-4 hrs graft away before the old girl rumbles into life - fingers xd etc