BKD engine rebuild

[dynamik]

Ok so basically I own a Seat Leon with a bkd engine I purchased it at 44000 miles as standard from seat dealership and since then I have made some power modifications to it like a Turbo Dynamics hybrid turbo, S3 intercooler, hard pipe kit and egr delete from Darkside at 108000 miles. The car was a dream to drive with 221bhp and 452nm of torque.
Unfortunately after a while my tandem pump fitted to the cylinder head decided to fail internally resulting in a diesel runaway on the motorway, after a few minutes trying to safely pull over I put it in 6th gear and slammed the brakes on making the engine stall (turning the key did nothing).

I had the car recovered by a local garage that suspected the tandem pump as a failure so I purchased a new one from TPS, when they opened the boost hose next to the intercooler apparently 18 litres of mixed diesel and oil spilled all over the floor. Surprisingly there was no damage to the turbo shaft wheels or bearings. all in all the work they did cost me the best part of £700 and they said that there could still be further damage in the engine but the costs were too much so I decided to collect the car as it was ok to drive and sounded fine after the new pump was fitted.

So at first I drove it calmly every time with no flooring it to see how it was and then after a few weeks gradually give it more boost. I noticed there definitely wasn't the power it should of had, so I removed the turbo and disassembled it. The vnt mechanism was caked in copious amounts of soot, so cleaned it and refitted back on the car, there was an improvement but not enough. Then I would get boost spikes where no power in 2nd and lots of black smoke out the back.

So I finally decided I would take the car off the road for a while remove the engine and gearbox and see what was wrong.

The first thing I noticed was the silicone hose bend connected to the turbo to the intercooler had a split where the clamp had dug in it when it was tightened up but it shouldn't of happened so darkside had send me a replacement.

I then started disassembling the top half of the engine.
[//s1253.photobucket.com/user/dyenamik1/media/Mobile%20Uploads/20170122_170258_zpsvdrdwxgn.jpg.html]
[IMG]C:\Users\Sean\Documents\Bluetooth Exchange Folder\20170122_170258

I noticed there a little bit of wear to the camshafts but still perfectly ok to reuse.

I then removed the cylinder head from the block and got a little surprise,

Then the camshafts, the bearings are shot

I then looked at the underside of the head and found what I believe to be the culprit of the damage to the piston, bearing in mind this is revision c head,

cracked on all 4 glow plug holes. So obviously I would not be reusing this head or getting another vw replacement. after removing the block the I could see the gearbox bell housing was full of oil that had leaked through the rear main seal.

After cleaning the piston revealing the damage,

So with that in mind ordered 4 new pistons from TPS and started the rebuild process, first getting the block a light hone, cleaned, degreased and the crank polished.
When I got it back it was like new,

I got the machine shop to remove the oil pump sprocket from the crank and I fitted a brand new one by heating it in the oven for 15 mins at 220 deg and slide it in place, as it cools it grips to the crank.
Now starting installing the new main bearings and thrust washers,

then the crank,

then main bearing caps with new main bolts (do not reuse ,these are use once only stretch bolts)

then the nice sight of brand new pistons, I reused the conrods as there was no damage to them and new bolts.

At the moment the engine is like this

with brand new oil pump ,chain and tensioner awaiting for more new parts to be fitted. It will be basically a brand new engine when complete as everything is being replaced with new vw items.

Sorry if this was a very long post and I will continue with the rest of the project when more parts arrive.

 

[Mac]

You have to upload photos to photobucket and then put the link of image here.

Sounds like an interesting build, i hope you are going for a BIG turbo!

 

[dynamik]

I have tried but because I haven't made 15 posts I cannot insert an image, unless I'm being a noob and doing it wrong

 

[dynamik]

Ok so basically I own a Seat Leon with a bkd engine I purchased it at 44000 miles as standard from seat dealership and since then I have made some power modifications to it like a Turbo Dynamics hybrid turbo, S3 intercooler, hard pipe kit and egr delete from Darkside at 108000 miles. The car was a dream to drive with 221bhp and 452nm of torque.
Unfortunately after a while my tandem pump fitted to the cylinder head decided to fail internally resulting in a diesel runaway on the motorway, after a few minutes trying to safely pull over I put it in 6th gear and slammed the brakes on making the engine stall (turning the key did nothing).

I had the car recovered by a local garage that suspected the tandem pump as a failure so I purchased a new one from TPS, when they opened the boost hose next to the intercooler apparently 18 litres of mixed diesel and oil spilled all over the floor. Surprisingly there was no damage to the turbo shaft wheels or bearings. all in all the work they did cost me the best part of £700 and they said that there could still be further damage in the engine but the costs were too much so I decided to collect the car as it was ok to drive and sounded fine after the new pump was fitted.

So at first I drove it calmly every time with no flooring it to see how it was and then after a few weeks gradually give it more boost. I noticed there definitely wasn't the power it should of had, so I removed the turbo and disassembled it. The vnt mechanism was caked in copious amounts of soot, so cleaned it and refitted back on the car, there was an improvement but not enough. Then I would get boost spikes where no power in 2nd and lots of black smoke out the back.

So I finally decided I would take the car off the road for a while remove the engine and gearbox and see what was wrong.

The first thing I noticed was the silicone hose bend connected to the turbo to the intercooler had a split where the clamp had dug in it when it was tightened up but it shouldn't of happened so darkside had send me a replacement.

I then started disassembling the top half of the engine.


I noticed there a little bit of wear to the camshafts but still perfectly ok to reuse.

I then removed the cylinder head from the block and got a little surprise,


Then the camshafts, the bearings are shot

I then looked at the underside of the head and found what I believe to be the culprit of the damage to the piston, bearing in mind this is revision c head,

cracked on all 4 glow plug holes. So obviously I would not be reusing this head or getting another vw replacement. after removing the block the I could see the gearbox bell housing was full of oil that had leaked through the rear main seal.

After cleaning the piston revealing the damage,

So with that in mind ordered 4 new pistons from TPS and started the rebuild process, first getting the block a light hone, cleaned, degreased and the crank polished.
When I got it back it was like new, good news I was told I could use brand new standard sized bearings

I got the machine shop to remove the oil pump sprocket from the crank and I fitted a brand new one by heating it in the oven for 15 mins at 220 deg and slide it in place, as it cools it grips to the crank.
Now starting installing the new main bearings and thrust washers,

then the crank,

then main bearing caps with new main bolts (do not reuse ,these are use once only stretch bolts)

then the nice sight of brand new pistons, I reused the conrods as there was no damage to them and new bolts.

At the moment the engine is like this

with brand new oil pump ,chain and tensioner awaiting for more new parts to be fitted. It will be basically a brand new engine when complete as everything is being replaced with new vw items.

Sorry if this was a very long post and I will continue with the rest of the project with photos when more parts arrive.

 

[Legojon]

Unfortunately after a while my tandem pump fitted to the cylinder head decided to fail internally resulting in a diesel runaway on the motorway, after a few minutes trying to safely pull over I put it in 6th gear and slammed the brakes on making the engine stall (turning the key did nothing).

Wow, that was smart thinking. I always thought if that happened, I'd just turn the engine off. I'd myself once I realised the key didn't work.

 

[dynamik]

When it happened I did not realise it was my car at first being in the fast lane of a busy motorway, looked in the rear mirror with black smoke filling all lanes. I did try the key at first but nothing happened so I had to navigate through each lane to pull over. once I stalled it I left in for 10 mins tried to restart, it idled ok for 10 sec then as soon as I depressed the clutch pedal it went again so I had to dump it once more.