Smoky BKD 140

[Pimped up vario]

You don't hang about for someone who's out of practice. The nippers under my feet slow me down a fare bit. Are the able to pressure test the head when it's off the car. I thought it was a leak test were they put it up side down and put fluid be it petrol or diesel in the valve seat recess and check for it draining away indicating a loss of compression. Or are they going to pressure test the galleries for transfer from coolant to oil gallery passages?

 

[Stonesie]

They bolt a rubber mat with a metal backing to the face of the head and block off all the coolant holes except one, they connect that to compressed air and put it in a water bath to look for bubbles.

I now have the head off and heater plugs out, I couldn't get the injectors out and will get it to Headmasters in the morning, he can do that.

As for work, turns out I have a week off which I had forgotten about. after much laughing by my colleagues and supervisor I came home and got on with it. I will also get them to test the EGR cooler, that was the first thing he said on the phone, to check that first.

I hope they find something.

 

[Pimped up vario]

I'm sure you do hope they find something after all that work. Hope you get her sorted.

 

[Stonesie]

No fault's found, hes getting me a new head gasket/bolts and doing a minimal skim anyway and I'm just about to go to Euro car parts for the bits i need...

I'm out of ideas, I didn't notice any cracks in the bores but will have a better look, the turbo is not water cooled so that's not it.

Hope it was just a very light head gasket leak. Tomorrow I will bolt it all back together if it stops raining.

 

[Stonesie]

Collected all the stuff, he did find a 'low point' at the back of cylinder 3 on the head, he had to skim 0.003" (0.0762mm) to get rid of it, the steel shim head gaskets are not tolerant of such things so I'm hoping that that's it.

I wish I could get the car into a heated garage but nope, when it stops raining I will get layered up and get out there.

Might call VW and get some replacement injector bolts though, i'm not overly happy about reusing stretch bolts.

 

[spud31]

defo use new injector bolts, and the rocker bolts and cam cap bolts all need to be new

 

[Stonesie]

I have ordered injector bolts from the local VW dealer, will ask about the rocker bolts and torque settings tomorrow when I go to collect them.. Strangely, they only had 7 in stock, the parts guy was very apologetic about it... Not that I got much done today in a storm so there's no mad rush.

 

[Pimped up vario]

Is the rocker cover on your engine plastic? If it is then the torque setting will be really low and you wouldn't need new bolts for the rocker cover. Injectors bolts yes, cam cap bolts yes and cylinder head bolts yes. I'd use new gaskets everywhere that you've removed any.

 

[Stonesie]

Today I got the new bolts from VW, injector and injector rocker bolts and promptly snapped 2 injector bolts... My smallest torque wrench didn't go low enough and over did it, thought it was worth a try but no that's cost me another £100 (£20 ish for another set of bolts and about £80 for a proper Norbar torque wrench.

Also I spent about an hour and a half looking for some bolts to put the plastic coolant union back onto the side of the head, as I was packing up I had one last check under the bonnet and what's sat there in the drivers footwell

Which silly bugger put them there for safe keeping, that would be me.

Headmasters do good work, and only supply Elring or Payen gaskets, not cheap but they're worth it.


Tomorrow I might even get a jack under the engine to get the mount off and change that water pump and fit the new belt kit...

 

[Pimped up vario]

I had to torque up the compressor wheel retaining nut on my turbo and my torque wrench didn't go low enough. My solution was to measure the length of my sliding gauge torque wrench, the one were the bar bends and a needle points to a figure on a plaque, and worked out what force was required at that length to generate that torque value. Then I got the kitchen scales and calibrated them using a measuring jug and one litre of water. Then used the scales to push on the torque wrench until the weight I was after showed up on the scale display. It worked just fine. See if you can leave it back and get your £80 back.

 

[Stonesie]

That is ingenious, I thought about it myself but I don't want to annoy the Mrs, I remember about 10 years ago me and dad used the oven to heat a hub for a bearing change, my mum went ballistic... So kitchen stuff stays separate from the car stuff.

I don't mind having a smaller torque wrench, it might come in handy for the bike in the future.

 

[Pimped up vario]

Yeah, they don't like it when you use what comes to hand . I used my mum's wooden spatula to cushion the face of a piston caliper when pushing it back in. It never seen the kitchen again. Your works coming along nicely. I have a slow coolant leak at the minute requiring top twice a week. I don't have the time or intention to take heads off so I hope mine is a radiator or water pump gasket.

 

[Stonesie]

Another hour on it before the rain started, injectors torqued down, injector rocker shaft torqued, heater plugs in and rocker cover on, egr cooler on and all the coolant pipework loosely fitted.

I did enjoy getting out on the bike, heavy traffic is not a problem

I'm not looking forward to repriming the fuel system...

 

[Stonesie]

Not quite fixed yet, it has the new timing belt kit on and the cooling system is refilled, but when I turned it over the new fuel filter decided it didn't want to seal thankyou, shared it's fuel with the auxiliary belt... I will have a better look tomorrow, might even re-use the old seal.

I'm not having much luck with EuroCarParts, the thermostat was for a Peugeot, the timing belt kit was wrong and the fuel filter doesn't seal...

 

[Pimped up vario]

Does the fuel filter have a knuckle duster shaped seal. Not a great description I know. It's like five wee rings. The one I changed was blue, if that matters at all.

 

[Stonesie]

Sadly not (Perfect description btw), I will fish the old fuel filter out of the bin and use the old seal I think... This car hates me for messing with it lol I must have changed dozens of these filters in my life and this is the first one that's failed to seal, typical...

 

[Stonesie]

So the filter is now sealed and it runs, after 3/4 of an hour running on the drive I took it for a 60 mile run. it was smoky at first but that was expected with all the assembly lube and oil on threads ect.

When I got home I gave it a rev and it smoked just like before, over £600 in parts and special tools + who knows how many hours and it's exactly the same except one thing. The lower radiator hose was cold to the touch after all that running, the temperature gauge hasn't budged from 90.

I'm out of ideas. Other than change the thermostat tomorrow and see if that sort's the cooling.


I did notice some oil in the turbo intake side but cant feel much play in the turbo shaft, just the tiniest little bit.

 

[Stonesie]

After another go at bleeding the cooling system I found that it was already properly bled, then the wind dropped to nothing so a good old rev and I went for a sniff at the cloud my car had just farted out... OIL!!!

Taking it to a mates garage tomorrow for his opinion, if it is the turbo then I can only afford a core, not a complete recon unit... How hard can it be?


http://youtu.be/eHIvWhX0Ivk


I'm starting to feel like this with it now lol
http://youtu.be/C3GWgBXsqeg?t=8s

 

[Stonesie]

Ok so it's not oil, booked in tomorrow to have the timing re-checked, the mechanic commented that these engines are a sod to get right...

 

[towcester vag]

dont know where he got that idea?
they time up nicely if you know what your doing!