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I hit **** with sticks!
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Hmmm, some interesting impact damage there. Hopefully the mayhem didnt crack the head or any of the pistons. The damage in the one cylinder is from the chunk of valve that is missing. Looks like it bounced around in there a bit. How does the top of the pistons look? Check the turbo. I know you said the tensioner failed, but just check to be sure no turbo blades got inhaled into the engine instead.
 

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Discussion Starter #42
Hmmm, some interesting impact damage there. Hopefully the mayhem didnt crack the head or any of the pistons. The damage in the one cylinder is from the chunk of valve that is missing. Looks like it bounced around in there a bit. How does the top of the pistons look? Check the turbo. I know you said the tensioner failed, but just check to be sure no turbo blades got inhaled into the engine instead.
will get pics of it tomorrow so you can see for yourself,
 

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Discussion Starter #45 (Edited)
Hmmm, some interesting impact damage there. Hopefully the mayhem didnt crack the head or any of the pistons. The damage in the one cylinder is from the chunk of valve that is missing. Looks like it bounced around in there a bit. How does the top of the pistons look? Check the turbo. I know you said the tensioner failed, but just check to be sure no turbo blades got inhaled into the engine instead.
heres the top of the pistons, and also, i dont believe that the tensioner was the problem, the belt has a little rip in it and also you can see where it skipped on the teeth, and the turbo blades are all good

(pics go from the pistons from left to right)





and also, i got a "gift" (if thats wat you want to call it) from the guy i bought the car off of


^but i plan on actually getting a new intake instead of the filter
 

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I hit **** with sticks!
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heres the top of the pistons, and also, i dont believe that the tensioner was the problem, the belt has a little rip in it and also you can see where it skipped on the teeth, and the turbo blades are all good

^but i plan on actually getting a new intake instead of the filter
Wow, quite a bit of damage there. My theory without it in front of me would be that when the tensioner gave, or the timing belt, pieces broke off of the valves when they kit the pistons, and rattled around in there and caused all that impact damage. Another possibility is there might have been some overheating involved. On a VW 1.8, its almost always the tensioner.

If you havent actally removed the tensioner, I would pull it and inspect it, its what holds it tight that usually fails, not the pulley itself... If its still good its been changed at least once, and the timing belt could have been neglected and failed. Turbos can go boom, and pieces of them can make it into the engine, but that depends on the design of the intercooler, that will normally catch large pieces...

I would do a full rebuild, or just get another engine at that point. Too much damage to the tops of the pistons to run them for my taste. Make sure you replace that tensioner and belt no matter what you decide to do.
 

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As for the pic, the size is a little big, but the picture is too painful to focus on IMO... *chuckles*

We had an engine in Tech school with pistons that looked like that, it was an overheat with an aluminum head, and the hardened steel valve seat dropped, and broke to pieces while running at higher RPM... It was a 4 popper in an Isuzu Trooper. The side walls of the cylinder had been scared, and the piston looked like that... so we just used a hone and a lot of elbow grease to work out the scars, then we measured and bought the right size piston and rings... changed only that piston, engine still in the truck. Got a remanned head, and away it went!

I don't know, I guess I'd run with those pistons, but I'm a cheapskate.
 

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I hit **** with sticks!
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I don't know, I guess I'd run with those pistons, but I'm a cheapskate.
You could, maybe smooth out those cuts a bit, they are very tight engines, not unlike our 3.2/5's. It would likely run, but I wouldnt do it, couldnt sleep knowing the damage was there, all those holes arent great for the combustion process either.
 

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Hehehehehe, Dan, you also are used to doing work for someone else, and NO TECH wants a call-back... those don't generally pay, and the last thing you want is to wrench for free for a second time... So, yes, replacing the pistons the first time around isn't a bad idea.
 

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I hit **** with sticks!
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Hehehehehe, Dan, you also are used to doing work for someone else, and NO TECH wants a call-back... those don't generally pay, and the last thing you want is to wrench for free for a second time... So, yes, replacing the pistons the first time around isn't a bad idea.
In all honesty, I wouldnt want a comeback for myself either, lol...my way is do it all right the first time, or time for bushes and leaves...there are some areas where its just not worth it to "save", or "let it fly"...
 

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Discussion Starter #55
my order came in today :D

also did a "little mod" -still not done with it, need to paint it some more, but its a plastic vw logo that i put over the cup holder hole, so far so good :D
 

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But what about holding cups?

Well, wait - that is a Geman car, and most German cars did not come with cup holders till recently (last 10 years)... to the Germans, BMW specifically, Cars were used to drive, as tools, not as living spaces and comutermobiles that needed to hold expensive coffees... Do DRIVE was the experience...

So, I dig the mod...
 

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Discussion Starter #57
But what about holding cups?

Well, wait - that is a Geman car, and most German cars did not come with cup holders till recently (last 10 years)... to the Germans, BMW specifically, Cars were used to drive, as tools, not as living spaces and comutermobiles that needed to hold expensive coffees... Do DRIVE was the experience...

So, I dig the mod...
well i have 2 more cup holders, but if i ever feel the need to use this exact one, the logo pops right out, so i can use it as a cup holder also,
 

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Discussion Starter #58
heres a bunch of pics i took today,


right side

2 middle ones
found out what caused all the damage, found it inside the head while i was changing the valve stem seals, it was a piece of the broken exhaust valve

here is a pic of the little piece that caused all the damage and the broken valve

here is when i fitted them together to see if it was a match, yes its a match, might now look like it because of the damage to the broken off piece
 

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Discussion Starter #60
im currently in the process of putting the engine back together, ALMOST THERE!, I ordered head bolts and a knock sensor(since i broke mine) yesterday which is suppose to be coming in tomorrow :D Now all i need to do is find the special head bolts tool and put the engine back in the car this weekend
 
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