[Vwdiesel] 1.9 diesel with some issues - oil, valves, not running,etc.

[Sandy Cameron]

At 07:27 AM 14/01/05 -0800, you wrote:
>
>I'm going down to pull a 1.9 diesel from a Vanagon on Monday. I'm getting
it complete (longblock, pump, manifolds, no accessories) for $150 as it has
some "issues." 
>
>Engine history (as I have been told): 
>
>The engine came from Overland in Ca. It was installed in the Vanagon about
2,000 miles ago by a previous owner (about 2 years ago). The current owner
bought the van and drove it for a while until it "blew."  He pulled the head
and found that two pistons are marred (1 & 3) and the head has some bent
valves. He also indicated that it was blowing some oil out through the
dipstick on occasion.  The timing belt was intact and did not appear to have
slipped (from owner's interpretation). It ran fine up until "the incident"
after which he parked the van and started his investigation into what
happened. His determination was inconclusive.


This is almost certainly the failure of the crankshaft sprocket "key".

This is a distressingly common failure of the early IDI 9.9 engines.

NEVER loosen the center bolt to change a timing belt, always loosen the 4
pulley screws and remove the pulley, exposing rhew sprocket and belt, and
don't hold the engine by the center bolt when removing the screws.

The car below was on it's way home from a timing belt change at a non-volks
shop, when it blew.

2 years ago, a gasser-only repair shop friend dragged a 93 passat into my
driveway and asked me to look at it.
When I got the head off, found bent valves, crunched lifters, etc.
Puzzeling over the engine, with the head off, noticed the pulley sometimes
didn't follow the engine when cranked, and it looked a bit crooked.
I thought "shit, the c-shaft is broken"
Later I learned that this is not uncommon, there is a fix (ask a shop, I
don't do them) and VW changed the keying before they got to the TDI version.

I have heard there is a special replacement sprocket available from VW, and
a shop can machine a flat on the shaft to match it, so it can be recovererd.
Heard it can be done on the car, too.

My 94 Jetta has over 100,000 miles on it, no problem, 2 timing belts changed
so far.
Good luck, 

Sandy.
VE3AAC