Help! Where to next?....

Hi there


I wonder if anyone has had a similar experience with the following or could help never-the-less.


I have recently purchased a 1996 D1 XS auto (300 tdi), which is a non-runner. The previous owner said he was driving down the motorway and the engine just stopped and the car hasn't started since. I think that the engine is to blame but having spoken to others, I am not ruling out the auto box.


So far.....


I have taken the aux belt off and the glow plugs have come out. No change. I then proceeded to try and turn the crank manually. It didn't move clockwise but did turn back for approx one turn then locked solid again. I then turn clockwise again for approx one turn and it locked up yet again.


Then....


I removed the cover to expose the adjustable pulley on the pump and took the rocker cover off too. When you turn the engine, the pump and rockers move.


Now...


I'm scratching my head. Can anyone shed any light?


Thanks
Tom

Has the belt jumped and bent a valve.

Jamo36599 said:

Has the belt jumped and bent a valve.

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Is this common? I've not heard of that before?

Not sure. If its spinning by hand and stoping dead could be an option

Head off it is then!

Strange symptoms

Might be a disaster or something simple.

Could it be the auto box?

Take the timing belt off and then take all the push rods out.
The crank should turn with the belt off.
If it is still getting stuck then the head will need to come off.

Could I not just take the rockers off and see how the valves sit?

I've almost got the head off now.

What i'm not sure of though is the first rocker had about 3mm of slack in it? Do you think there could be trauma underneath?

I'm only a novice, but 3mm is a lot when the gaps are measured in 1000ths of an inch. What's 3mm in imperial? 8th of an inch?

Steviecops said:

I'm only a novice, but 3mm is a lot when the gaps are measured in 1000ths of an inch. What's 3mm in imperial? 8th of an inch?

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about that ,

The gap on the rockers should be 0.20mm

I've almost got the head off now but i'm convinced that there will be some sort of valve damage.......

So, i've just got the head off and it looks like no.1 piston has melted and disintegrated. No.2 bore looks like it was just about to follow suit.

There is a little bit of melted piston in the valves of no.1 but I think I'll be able to salvage the head without too much fuss.

As for the block, I can get a second hand one for about £150 but i'm not sure where to repair/rebuild the one i've got.

Anyone have any thoughts?

Ouch! Wonder what caused that?

usually poor injectors ,you cant just fit any piston to any block ,block is bored to the piston size pistons vary in size by a good few thou and clearance between piston and bore is just over a thou

I reckon that it overheated as the collant was very low. If it was injectors then I'd love to know how I can test as I wasn't thinking of replacing them.

it would have melted head if it had over heated that badly ,put some pics up