1Z Tdi install photo diary

[max and caddy]

Looking good there Dave...when you sending them off to the platers?

[T'Onion]

looking smart Dave

[Titus A Duxass]

I like the Racing Red Oxide.

[futbus]

Few more bits done, mainly parts back from platers and the painter next door ( Wedges Workshop) were a bit bored waiting for paint to dry, so I asked if they had any spare bottom of tin paint left. So the block is now painted in Roll Royce Red, although it looks alot brighter with the camera flash.





We sent all the pulleys and front plate off to be plated. These are CAD plated then covered with a black coat. It saves on painting and works out cheaper in the long run.





All the sump bolts and Cam cover caps also done along with the pulley bolt. Came back looking like new.



We had a couple of sets of the water pump bolts looking a bit past there best, although they now look a little different,



Started stripping the head, with the cam and caps removed. Followers taken out, glow plugs and injector clamps.



We managed to get only one of the injectors out using the slide hammer, tho it needed quite alot of grunt. The other 3 refused to move so they are being left to soak over night and try again tomorrow. You can see the alloy corrosion around the injectors which should soften with some spray to help.





Hope to have the head complete stripped by the weekend, so the rebuild can start with all new and clean parts.

[max and caddy]

if you cant shift those injectors stick the head in front of a space heater and get it so hot it smokes..then try again..might just unstick them.

[futbus]

Not much spare time due to other conversions, but stripped the turbo down to be cleaned. The bearings all feel fine with no end play so no need to send off for a rebuild. If there is no play the unit can still be stripped for cleaning as the main impellers and bearings are not taken to bits disturbing the balancing which needs to be done by specialists as they are spun up to 20k plus.



Stripped down to the main components



Fresh air side is a bit covered with oil



Exhaust side



Exhaust waste gate covered in carbon



Fresh air side impeller



Exhaust side impeller



All this will be going in the ultrasonic cleaner tonight to get all clean and rebuilt with the main body re-indexed so the oil ways drain properly into the sump.

[Iceworx]

Loving this thread

[futbus]

Ok we spent the evening cleaning and putting the turbo back together,

After some time in the pot they took some time to get off the 15 years of accumulated crud and they would do well to get soda blasted just to bring the sparkle back, but were not looking for a show engine, just functional and clean.



The rotors came up alot cleaner,





and back all together ready for re installation

[Iceworx]

Seeing the before and after photo's that's just convinced me to buy an ultrasonic cleaner

[keith]

will you be fitting a chargecooler...or intercooler ???

[futbus]

The engine will be getting a charge cooler, but a fair bit to do before we get to that.

Still fighting with the stuck injectors, but need to get them out soon so the injectors can go for cleaning and pop testing and get the head all cleaned. Still working on customers vans so no real time to work on this, but doing a bit when we get time.

Really want to get everything clean so we can start rebuilding.

[jes*b]

Great stuff Dave. A real education, thanks

[max and caddy]

The engine will be getting a charge cooler, but a fair bit to do before we get to that.

Still fighting with the stuck injectors, but need to get them out soon so the injectors can go for cleaning and pop testing and get the head all cleaned. Still working on customers vans so no real time to work on this, but doing a bit when we get time.

Really want to get everything clean so we can start rebuilding.

tryed heating the head up yet? space heater, big oven, barbecue it even but the heat will loosen the grip on the shafts...normally just giving the engine a good whipping up the road to get it hot will allow them to move but as yours in a million bits...some of the new common rail engine injectors are a right facker to get out but an extra large slide hammer normally shifts em with a hot engine.

[camper]

If its heated up in an oven or barbecue a ally cylinder can warp.

[max and caddy]

kinda joking about the barbeque...and yep in theory it could warp...but then a slide hammer could break a big lump off it, or the world could cease to spin on it axis...it works and when theres little to lose?