Engine overhaul advise - 1.9 TDi BXE Jetta 5

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Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Tue May 15, 2018 1:30 pm

Hi Guys,

New to this forum.

I am overhauling my motor, any advise or tips to be aware of?

I need some advise - how important / serious is it to renew bolts - (Head / Conrod / Bearing cap etc...)

Thanking you in advance.

I am based in Durban.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by BIGMIG » Tue May 15, 2018 2:26 pm

Hi and welcome.

Im really not trying to be rude but if you are going to be overhauling your own motor then you should already know the basic to mid level stuff about PD diesel and petrol engines. Like "how important / serious is it to renew bolts - (Head / Conrod / Bearing cap etc...) ". They all need to be replaced.

To undertake the rebuilding of a motor without any guidance or knowledge is very risky. Yes you are asking for guidance here but its not the same as having someone experienced there with you. If you get something wrong it could turn out to be a very very costly fix.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by billionairebum » Tue May 15, 2018 2:30 pm

+1 on that.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by Ashveer03 » Tue May 15, 2018 7:16 pm

All TTY bolts must be replaced.

I would suggest doing a proper rebuild not just a "rings and bearings" thing. Do it properly the first time or it will end up being a money pit.

Whats the reason for the rebuild though?

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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by Unobeat » Wed May 16, 2018 8:04 am

Totally agree with the guys
Do not take short cuts on the rebuild, do it properly.
THANAS wrote:Mix them together to create Shellstrol, and then mix that with Winstrol to create the ultimate, maximum performance oil for your engine.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Wed May 16, 2018 12:00 pm

Hi BIGMIG ( no offense taken :-) and greetings to all of you.

Yes I am been guided by a mechanic and just getting a 2nd/3rd opinion..

My lifters were worn and had wholes on the top... they broke broke. The cam shaft also had bad wearing in that same area.

I broke the rear crank seal when stripping it.. and also replaced that.

The block and head are back from the Engineers and all was ok. New valves, guides ... new oil pump (due to metal pieces) and other bells and whistles etc... new rings and bearing... Sitting on total spend of +- R10k...

I was just wondering about the bolts, they rather expensive... and any other tips you may have...

Thanks in advance.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Wed May 16, 2018 12:04 pm

Ashveer03 - The lifters broke and therefore caused a terrible sound... decided to strip it down and start again.

i also think it was over-fueling from the amount of diesel i found. I am buying a kit for my injectors from Bosch ...

Oh guys I am not a mechanic :-) I just learn as i go and enjoy it...
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by billionairebum » Wed May 16, 2018 12:46 pm

Ok, well in that case you should be ok. What km was the motor on?
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by Deranged_9n3 » Wed May 16, 2018 1:06 pm

Use new head and cam cap bolts. Cam cap bolts is R180 a set and not sure of headbolts price. Also not sure about bolts on conrod but I would advise you change them too. Once a bolt had been torqued your don’t want to re use it

Hope they didn’t leave ANY shavings behind after skimming the head, I have lost 3 injectors back in the day due to shavings in the head ( PD motor )

Also, to replace cam and lifters you don’t need to remove head. Unless you had hit valves offcourse ?
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Wed May 16, 2018 1:18 pm

Hi Deranged_9n3

New Conrod Bolts R 479 + head Bolts R 997 (Agent) VW

Thanks for the advise i will be sure to replace them also.

I had no issues with valves ( I just stripped everything to check and see if there was further damage) the head had no issues also.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Wed May 16, 2018 1:21 pm

Hi billionairebum,

1st time doing motor it was on 345k. so that is why I am not so heart sore about it.

The car has been good to me! :-)

I am a bit worried about the Turbo, there is slight play.. I will decat it myself on the week end....
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by Ashveer03 » Wed May 16, 2018 2:30 pm

Such cam and lifter wear is common on these engines when incorrect oil is being used. I hope u bought a new cam and set of ina lifters..

Injector seals are cheapest at diesel electric (bosch seals)

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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by billionairebum » Wed May 16, 2018 2:36 pm

DenzJ5 wrote:
Wed May 16, 2018 1:21 pm
Hi billionairebum,

1st time doing motor it was on 345k. so that is why I am not so heart sore about it.

The car has been good to me! :-)

I am a bit worried about the Turbo, there is slight play.. I will decat it myself on the week end....
Thats not bad mileage.
My old Highline ran to 330k without the motor being touched but she was in serious need at the end.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Wed May 16, 2018 3:10 pm

Ashveer03 wrote:
Wed May 16, 2018 2:30 pm
Such cam and lifter wear is common on these engines when incorrect oil is being used. I hope u bought a new cam and set of ina lifters..

Injector seals are cheapest at diesel electric (bosch seals)

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Yes Sir, all new ! yes they are cheap I am getting new ones.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by Ashveer03 » Wed May 16, 2018 3:26 pm

All the diesel u have found could be from the internal fuel passage.. when u remove the injectors all the fuel from that passage will leak into the combustion chamber.. but anyway, the seals and bolts must be replaced every time the injector is removed. Be sure to read up on it when refitting, injectors have to be a certain angle and correct lash (rocker adjustment)

Dont forget a cambelt kit, even more because u had cam failure..

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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by Unobeat » Thu May 17, 2018 6:40 am

DenzJ5 wrote:
Wed May 16, 2018 1:21 pm
Hi billionairebum,

1st time doing motor it was on 345k. so that is why I am not so heart sore about it.

The car has been good to me! :-)

I am a bit worried about the Turbo, there is slight play.. I will decat it myself on the week end....
That is good kilos on the motor.

Please start a rides thread and upload pics of the rebuild.
I want to follow it.
THANAS wrote:Mix them together to create Shellstrol, and then mix that with Winstrol to create the ultimate, maximum performance oil for your engine.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by BIGMIG » Thu May 17, 2018 9:03 am

Ashveer03 wrote:
Wed May 16, 2018 2:30 pm
Such cam and lifter wear is common on these engines when incorrect oil is being used. I hope u bought a new cam and set of ina lifters..

Injector seals are cheapest at diesel electric (bosch seals)

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This is not true. I had cambelt failure due to lifters been worn, alsways used to correct oil and changed at 7.5k. The reason for them wearing out so fast is due to the very steep ramp on the cam. If you do some research you will find that most if not all aftermarket cam manufacturers have redesigned this steep ramp to help ease wear.

P.S if the manual states that you must replace bolts then you replace bolts and to replace with the correct type. Don't remove a stretch bolt with a HT bolt. Plus you will need new injector lock bolts and rocker bolts. Your basically going to be replace almost every bolt in the engine.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Thu May 17, 2018 2:50 pm

BIGMIG wrote:
Thu May 17, 2018 9:03 am
This is not true. I had cambelt failure due to lifters been worn, alsways used to correct oil and changed at 7.5k. The reason for them wearing out so fast is due to the very steep ramp on the cam. If you do some research you will find that most if not all aftermarket cam manufacturers have redesigned this steep ramp to help ease wear.

P.S if the manual states that you must replace bolts then you replace bolts and to replace with the correct type. Don't remove a stretch bolt with a HT bolt. Plus you will need new injector lock bolts and rocker bolts. Your basically going to be replace almost every bolt in the engine.
[/quote]

Hi BIGMIG,

Please advise what is the correct oil? for my car and the current mileage of 345k

and thank yo for the advise! appreciated.

Regards,
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by Ashveer03 » Thu May 17, 2018 3:17 pm

Not stirring up an argument but as far as i know (from some experience and threads on this forum and tdiforums), these engines are choosey when it comes to engine oils because of cam wear as the injectors are operated by the cam causing extra stress which we all know about. Certain oils are made taking the "pd" system into considerstion for that extra cam protection. Even with the steep lobe thing which i honestly did not know about (thanks mig) an incorrect oil will definitely cause premature cam wear and eventually failure.

I only use liqui moly toptec 4100 in my car and everybody elses that car i work on.
Some use shell hx7 av, some use motul and some even use castrol. I guess as long as its 505.01 approved..?
Too many threads with the type of oil debates.
Liqui moly does me good though, no complaints.

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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by BIGMIG » Thu May 17, 2018 4:18 pm

I get what your saying. We are looking at purely why they fail prematurely and that is down to oil. all the TDI that I know have always used the correct oil and a lot have had early lifter wear. Yes if you use incorrect oil I personally think it will accelerate the wear even quicker.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Tue Jun 12, 2018 9:52 am

Good day gentleman,

Thank you for all the advise and help, i have tried to search on the forum for similar faults but was not able to find anything smiliar.
Problems:
1. The car swings for over 10 seconds to fire up and start as if there is no diesel going through.. i have checked and the diesel is pushing through.
2. yesterday it fired up for the first time 11/06/2018 and its as if i have no TURBO... there is no power.I drive up to 3rd gear (+-60) and the car is crawling...

I have checked boost pipes last night and tonight i will check the Vacuum pipes and actuator...

Any other advise and if there is a VW Mac (Diesel) in Durban area / Pine town please can you give me your number..

Its been an expensive long project and i'm tired now... again I am not a mechanic...

Thanking you very much in advance!
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by DenzJ5 » Tue Jun 12, 2018 10:05 am

Oh i also get n Emissions workshop error ..
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by BIGMIG » Thu Jun 14, 2018 10:06 am

This is way to broad to try and diagnose over a thread. What was the extent of the rebuild, did the injectors get removed, were they aligned perfectly when reinstalling if in fact they had been removed, was the injectors set after, was the timing checked?

Is the turbo bolted on :lol:

There is a lot more questions and answers to diagnose why there is no power.
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Re: Engine overhaul advise - 1.9 TDi BXE Jetta 5

Post by panic-mechanic » Fri Jun 15, 2018 6:20 am

Possibly you got the cam timing wrong.
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