[Vwdiesel] Re: [Vwpickups] A TDI tale of woe and strife, hammers and PBlaster

[Hayden Chasteen]

I have considered the raceware but since the TDI uses a non compressing 
steel gasket, the old problems of head gasket failures are almost unheard 
of, so having the ability to remove the head without replacing the head 
bolts is not really a factor.  Although the Caddy will be chipped, the 
parameters of the chip are still well within the limits of the stock engine 
set up, so clamping forces is not a issue either, so I will probably stick 
to the stock bolts especially since COST is an issue! :^(   Hayden

----- Original Message ----- 
From: "william thompson" <thecraftedcow at comcast.net>
To: <dieseltdi at verizon.net>
Sent: Wednesday, January 25, 2006 10:39 PM
Subject: Re: [Vwpickups] A TDI tale of woe and strife, hammers and PBlaster


> What a sad story, but buck up..it could have been worse! You could have 
> removed the flash shield and found that the head was erroded under the 
> injector. That really is an expensive bummer.
>
> Are you considering using Raceware Fastner head studs instead of stretch 
> bolts? It is easier on the head, the gasket, and the person having to 
> torque it down. They only torque to 75#, and they are reuseable.
> Bill
>
> have you visited www.raceware-fasteners.com?
> ----- Original Message ----- 
> From: <dieseltdi at verizon.net>
> To: "VW TDI Mail List" <vw-tdi at yahoogroups.com>; "tdi conversions news 
> list news list" <TDI-conversion at yahoogroups.com>; "VW diesel mail list" 
> <vwdiesel at www.audifans.com>; "Audi-VW-diesels Mail list" 
> <audi-vw-diesels at yahoogroups.com>; "VW Pickup Mail list" 
> <vwpickups at neubayern.net>
> Sent: Wednesday, January 25, 2006 5:36 PM
> Subject: [Vwpickups] A TDI tale of woe and strife, hammers and PBlaster
>
>
>> For those of you that may wonder why you must have the injector "heat 
>> shields" (really just copper crush washers} and wonder why you can't 
>> just reuse the old ones....read on!  I have been working on the 1Z 
>> engine that I bought for my Caddy TDI conversion.  New belts, clutch, 
>> hoses, the usual stuff.  Well I also bought a set of high flow  nozzles 
>> and had them installed in some injectors that I had laying  around.  I 
>> pulled the stock injectors from my Jetta (they have been  in the car 
>> almost 80000 miles) to install the high flow injectors to  see how they 
>> run.  The old injectors slipped right out and the new  ones went right in 
>> no problems.  I drove them for about 2 months and  then pulled them to 
>> install them in my donor engine.  This seemingly  simple task has turned 
>> into the project from hell.  I spent a WEEK  trying to pull the injectors 
>> out of the 1Z engine. The would not  come out!  I could get them to turn 
>> but it was the top of the  injector unscrewing from the nozzle section. 
>> Finally out of frustration, I unscrewed the top of one completely, pulled 
>> out the innards that I could get and then filled the hole with PBlaster 
>> and  then waited a full week.  I screwed the two halves together but 
>> still  NO GO! I applied heat, I applied more solvent, I beat up the 
>> injectors with a hammer trying to loosen them  NO GO!  Finally out of 
>> frustration, I pulled the head, definitely not what I really wanted  to 
>> do.  I then disassembled the injectors (by now ruined anyway) and  used a 
>> punch to drive out the nozzles which were absolutely caked  with carbon. 
>> Fine I think, the nozzles are out.  Well the nozzles  were out but not 
>> the bottom part of the injector that holds the  nozzles.  After some more 
>> heating and putzing around with it, I  reassembled the injector with the 
>> nozzle portion inside but upside  down to give me a flat surface inside 
>> the injector to push against.   Using a old screw driver shaft with no 
>> handle, I put it through the  injector hole into the injector and pounded 
>> the injectors out one at  a time.  It took at least 5 good hits with a 
>> heavy framing hammer to  get each injector loose.  Each one was caked 
>> with carbon and the  holes were caked with carbon and guess what was 
>> missing? No copper  washers!  Now I have to buy a new head gasket and new 
>> stretch bolts  for the head (and expense I wasn't counting on).  Moral of 
>> story, the  crush washers are cheap, do try to save money by not 
>> replacing them when you remove the injectors, you will regret it later 
>> and make sure  to get the actual OEM washers.  Turns out most of the 
>> after market  washers are too big and will not seal properly and the keep 
>> the  injector from actually seating inside the cylinder.    Now to go 
>> take  some tylenol for my old, aching shoulders.  hayden
>>
>> Visit my website at:  http://mysite.verizon.net/resosxp8/mydieselpages/
>> Proud owner of:
>> 2004 Passat TDI GLS, 2.0l, 8 valve, 134 HP, 247 lb/ft of torque  (making 
>> 150 hp with Diesel Power Tuning Box), Blue Graphite,  Anthracite leather 
>> interior, ABS, ESP.
>> 1998 Jetta TDI (Wetterauer Chipset, 2 1/2" exhaust, K&N Filter,  140K + 
>> miles, and running biodiesel)
>> 1981 Rabbit Pickup -Awaiting a TDI engine swap with a 96 Passat 1Z 
>> engine.
>> And many, many, many VWs; from a 1946 Beetle (11 Beetles total), to  Vans 
>> (5 - 3 splitties, 2 bay window), Rabbits (3), Karmen Ghia (1),  Jettas 
>> (5), Passat (1), Dasher (1), New Beetle (1), and Rabbit  Pickups (3) most 
>> now gone but not forgotten.
>> 1982 Suzuki GS 650GL - resurected from a farm, now back on the road,  Old 
>> school bike for an old school guy!
>>
>>
>>
>> _______________________________________________
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>> Vwpickups at neubayern.net
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