Polo 1.9 TDi 110 bhp with broken engine

[neo]

You'll get the tap from J&L Industrial


******** VAG Tech Advice *********
If it dont run right cold, change the blue temp sender.
If it aint got a spark, check earths, coil connections.
If it idles like ****, clean the ISV and throttle body.
For all other problems, use a hammer

[bill]

Hi there Stan and Neo plus anyone else with any advice!

Here's an update, followed by the next bit I don't understand!

Bores honed out beautifully. New rings on the pistons, new big end bearings, and the bottom end all back together - feels right, pistons all at the right height and turning over nicely. So I'm happy.

As far as the glow plug goes, great advice. I bought a tap as you suggested rather than go straight for the helicoil. Got the tap from Snap On, ordered it online £4.40+vat and p&p - stunning value! And this is the good bit it has reclaimed the thread and the new glow plug tightened up feeling dead right.

The head was completely stripped so I lapped all the valves in and fitted new stem seals. I don't know much about hydraulic tappets (is it common to call them buckets?) but I cleaned them up and refitted them. I put the cam in following the Haynes manual and tighted up 2 and 4 bearing caps. Here's the odd bit - all the valves are open to some extent! I can only suspect that the hydraulic tappets have grown somehow? What's that all about? What do I do to sort it?

My sincere thanks again guys

Bill

[sick of cars]

Did the oil drain out of the tappets when you dismantled the head. The contact face should have been kept facing down as far as i know. They maybe ok after theyve had at least half an hour to "settle".

Knuckles are skinned when spanners slip.

[stan_deezy]

Agree with SoC above. They should settle. The engine should also be turned a few times by hand to ensure no contact then when you first start the engine you should do it so that the engine spins but doesn't start (disconnect fuel lines and collect fuel in a container). This builds the oil pressure up nicely throughout the engine and the tappets too. Reconnect the fuel and she should be fine.............ah the joys of giving advice from a long distance []

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Just hanging around.......

[bill]

Thanks again for the advice. The followers had actually 'settled' considerably overnight and once I'd turned the cam over a few times it all looked OK to me. So, the head is back on, new cam belt done, there's a chance I might get somewhere near finished tomorrow!

Cheers

Bill

[stan_deezy]

That explains why the paynes manual says "wait for 30 minutes after fitting new buckets before attempting to start the engine".... [] For once they may have got something right!

Hope it fires and purrs first time Bill! [8D]

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Just hanging around.......

[bill]

It's a runner!

2.6 miles completed and it sounds dead right, doesn't smoke at all, holds the right water temperature. I'm delighted, although I'm going to do a hundred or so miles before I give it back to the mother in law!

Many thanks to Stan[8D] and Neo[8D] for your excellent considered advice which has proven spot on at every step.

Cheers

Bill[]

[stan_deezy]

Aw shucks, no problem at all, now you've got me blushing! [:I]

You did all the hard work!

Absolutely delighted the car is a runner again and to think that the insurers would have written it off is just the best bit about the whole episode!

Must be a little flying machine too with the 110 ASV TDi engine in it?

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Just hanging around.......

[bill]

Hi guys

I've now done 130 miles and it's spot on. A couple of things you might be able to advise on: When it starts first thing there are a couple of tiny hick-ups in the first few seconds, probably wouldn't even notice them unless I was paying attention - any ideas on this? Second, the idle speed is about 950rpm - a shade high I think, how can I alter this? and what should it be? Finally, before I give it back is there anything I should do, check or replace?

Many thanks

Bill

[stan_deezy]

Don't know about the little coughs as it starts could just be normal(-ish) but the idle speed is identical to our ASV engines.

I reckon you've covered most of the things before giving it back, it shouldn't even need an oil change either for a while. Thing is if it goes wrong at least they can get it recovered back to your house and you'll know exactly what you're looking at []

Superb job by the way!

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Just hanging around.......

[neo]

Check there is a little bit of free play in the accelerator cable if you think it's running a bit quick. Autodata says it should be between 875 and 950 so you're doing alright i'd say!




******** VAG Tech Advice *********
If it dont run right cold, change the blue temp sender.
If it aint got a spark, check earths, coil connections.
If it idles like ****, clean the ISV and throttle body.
For all other problems, use a hammer

[bill]

I'm giving it back tomorrow - but on the way to the MOT test today I noticed that the water temp guage had dropped back to the end stop. It's done it twice now and then without warning resumes working normally. What do you reckon? Any offers of advice welcome as usual! Good news is it passed the MOT, the smoke test bit with flying colours.

Cheers

Bill

[karlykars]

for future reference you should squeze out the tappets in a vice before refitting them, this applies to just about all such tappets, good luck!

[neo]

Loose wire on the sender unit?


******** VAG Tech Advice *********
If it dont run right cold, change the blue temp sender.
If it aint got a spark, check earths, coil connections.
If it idles like ****, clean the ISV and throttle body.
For all other problems, use a hammer

[bill]

Hi there, I'm new here but I'm a VW fan of old and I've got a big problem to sort out. My mother in law was driving along in said Polo when she hit a big puddle and the engine stopped suddenly. Water was ingested and VW say it needs a new engine - gulp! It's a 51 reg car and its worth repairing. Any ideas where I can buy a recon or used engine. The engine number starts ASV. Any ideas, suggestions, or experiences of this type of failure most welcome.

Thanks

Bill