Mk2 Turbo Diesel Motor Rebuild

Is that a french fry I smell? No, that would by Christian's mk2 turbo diesel passing by :)

This originally started as an alternator belt tensioner install, but when he was on his way over he blew a head gasket. He had overheated the day before, and it eventually just failed :-(

Once we got the head off, we found that the head was cracked in a whole bunch of places, so that needed to be replaced too. Then, since he needed a completely new top end we made the decision to check the bottom end for damage... We hated to see the bottom end be bad due to the overheating after the new top end went on. Good thing we did, as he had a piston that was showing some skirt damage, and the rod bearings had a lot of wear on them... but that part was expected after the 200k miles that the car has seen.

So, we gave him the news, and he decided to fix it :-)

The car will be getting a brand new head, one new piston, all new gaskets and seals, new rings and rod bearings, and a new timing belt service. It should be ready to go for the weekend for him to pick it up, so this project will move right along :-)

Don't mind the air intake


Bad




New head


Some of the new parts



Update 3/6/08 10:00pm

We received the replacement piston today, we are hoping to have everything back together for tomorrow afternoon.

The one bad piston...good thing we checked :-)


New Head









Update 3/6/08 11:45pm

Calling it a night...we got two of the pistons in and everything else ready to be bolted on.


Yuck


That is much nicer




New piston rings vs. old


New vs. Old






Update: 3/7/08 12:45pm

All the pistons are in


This ring was cooked...




Update: 3/7/08 10:45pm


Everything went back together smoothly. The car kicked right over and runs better then it ever has!

Yuck