[cupa-joe]

Didn't get a chance to post this last night but here you go! This was THE FIRST attempt of start up.



After initial warm up I changed oil and found a couple issues.
-Turbo oil return had a 1drip per 5 seconds
-Fuel pressure gauge not reading(This makes 3 gauges so far)
-Rad fan blowing wrong direction which caused my temps to rise rapidly.

All of which I fixed today minus the fuel pressure gauge issue, I'm stumped on that. Suppose I'll order another one and try that.

 

[cupa-joe]

Got it all dialed in and took her out to get the break-in done. I followed the MOTOMAN method and feel pretty confident in it, felt strong all the way through. Came home and did my 20mile oil change after initial break-in and noticed an oil leak.

I pull my COP setup to find this... FML



Looks like the lifter seized, cracked the rocker and blew a hole in my beautiful VC. I found a pretty big chunk of my VC, but don't think it is all of it so looks like I'll need to drop the pan. Any suggestion? As far as clean up and such goes.

I'm gonna have to source out another VC, lifter, and rocker arm. Also have Dale take a look at the cam, looks a little chewed up on the edges.









It'll be down for a little bit longer, hopefully not much longer. It was a blast driving it and without PS was awesome.

 

[Sean485]

I would be amazed if you didn't completely destroy the valve seal and/or bend the valve.

 

[cupa-joe]

I would be amazed if you didn't completely destroy the valve seal and/or bend the valve.

That's just my luck.

 

[BogusSVO]

Damn it man. If it is an odd fail, seems you have the luck for it....

Bring me the cam, lifter and follower.

I have the follower and HLA to hand you.

Ill check for a VC.


Run a leak down on that cylinder, that will let you know if you have a bent valve.

 

[cupa-joe]

Damn it man. If it is an odd fail, seems you have the luck for it....

Bring me the cam, lifter and follower.

I have the follower and HLA to hand you.

Ill check for a VC.


Run a leak down on that cylinder, that will let you know if you have a bent valve.

Tell me about it, these things hate me for whatever reason. I'll do a leak down test and bring in the parts this week when I get a chance.

 

[serviceguy]

I may be putting a foot in my mouth saying this but would just a stuck lifter be enough to do that damage? In order to destroy the lifter that way and crack the rocker roller bearing I would expect the valve to be stuck closed as well hence causing the rocker to have no place to go when compressed by the cam.

 

[NY 95 TSI AWD]

What a bummer. Hope everything works out.

 

[cupa-joe]

Leak down and visual inspection showed no sign of bent valve which is a plus. Dale looked over the cams and those checked good, then hooked me up with a couple roller and a lifter. I took my VC to my local welder who has done all my work thus far and asked him what he could do with it. Looks like he is willing/able to patch this up and even make is visually pleasing. It won't be pretty for now but it will be hidden under the COP anyhow until I decide to get another VC.

So again, thanks to Dale for hooking it up short notice. Car should be up and running as soon as I get my VC back.

I know everybody loves pictures, so here you go. Haha





Still need a polished heat shield, might be hitting you up Steve!

 

[Red1991TSI]

Just let me know Joe. Did you see if that valve will open? I'd hate to see a repeat of the same issue.

 

[cupa-joe]

Just let me know Joe. Did you see if that valve will open? I'd hate to see a repeat of the same issue.

Yeah I'll run it through by hand once I get to that step before I finish it up.

 

[nfluck]

I'm so happy that you don't have to pull the motor apart again. And i spy my car in one of your pictures.

 

[Red1991TSI]

^^^Hey who let this shady character in here?

 

[Sean485]

Did you check the valve seal for damage? Seems likely that the valve retainer would have hit the valve seal and then smashed that into the valve guide.

 

[Blurred Talon]

Good to hear!

I'd likely flip out if that happened to me after rebuilding my motor. Hell, something like that is why I'm nervous to finish my car.

 

[cupa-joe]

Did you check the valve seal for damage? Seems likely that the valve retainer would have hit the valve seal and then smashed that into the valve guide.

Yeah valve seal visually looks perfect and unaffected. Seem like the lifter took most of the abuse, luckily.

Steve, I don't know who let this sketchy fella nFluck post but we need to look into it.

 

[cupa-joe]

Bled all the lifters and installed the cams. Turned it over by hand to make sure the valve opened and closed as it should, all checked good. Also got my Fuel Lab fuel pressure gauge and when I turn the pump on it jumps to 20ish then back down to zero. What gives?

Decided to replace my worn old steering wheel and gain some leg clearance while I was at it.

Momo Monte Carlo black/black and I went with the biggest at 350mm due to manual steering.







Before



After

 

[nfluck]

Oh snap!! Looks good man. Didn't know you were finally gonna get that steering wheel.

 

[cupa-joe]

Got the VC back





Threw a light coat of paint on it.



Good as new.



Still trying to figure out the no fuel pressure indication. So I replaced the expanding hose and fixed the power wire for the fuel pump. Drilled a hole, grommet, then ran the power wire straight through the assembly and connected it.

 

[cupa-joe]

Here is a clip of the idle.