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Head cracked? Help!?

Discussion in 'A3/S3/Sportback (8P Chassis)' started by s3reptdi, Sep 19, 2013.

  1. s3reptdi
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    s3reptdi Member

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    [Sep 19, 2013]
    Hi guys can you help.

    My brother broke down the other week he has a 2004 manual 2.0 tdi 8p. Lots of white smoke and the AA bloke diagnosed it as EGR valve.

    It got home and i scanned it with VCDS and there were no codes. I drove it up the street and there was no power and it filled the street with white smoke. I and everyone i spoke to about it said turbo, but i didnt want to jump to conclusions and waste alot of money on a turbo if it wasnt.

    A while back i changed the injector wiring harness and glowplugs and its been fine since, i did however read that the injectors can pack up after the problem was fixed so wasnt sure if it was that or not.

    I took the turbo air intake off and put a borescope camera down to see to compressor wheel spinning. Started it up and revved it up and the compressor wheel wasnt turning so that confirmed it was turbo.

    Took the turbo off to find the compressor wheel had broke off. I did a VW Caddy turbo at work and the same thing had happend the compressor wheel was in the exhaust!.

    When we bought the car it had a slight coolant leak from the pipe from the egr cooler to the heater matrix, i put two new jubilee clips on either end and it was much better. Ive since ordered a new pipe and propper clips. This was the only coolant leak its had. However when i drained the oil out whilst doing the turbo a tiny bit of coolant came out the sump. Obviously this isnt good and made me think headgasket. Ive pressure tested the cooling system and it holds pressure. I put the sump plug back in with the pressure on then took it out again and the same small amout came out (talking 100ml)

    Ive bit the bullet and started taking the head off, the number on the head starts with a C so from what ive read doesnt that mean it has the head that doesnt usually crack on?

    What tools do i need to set the timing up before taking the cambelt off? Any tips on timing it up as i know there common for being slightly out?

    How can i check the egr cooler is ok?

    Any tips/tools to recommend getting the injectors out and is it worth having them tested while theyre out?

    Obviously ill be doing cambelt and waterpump at the same time, are there any better makes for parts to use?

    Are there any specialists out there to send the head to, im really concious about it being cracked. We send heads away at work all the time but i doubt in my mind if they crack tested properly. Like my mate said when they crack test them theyre cold, obviously a crack will open up during heat which they cant do.

    If the head is cracked does anyone know anyone with a good one for a good price?

    Sorry for the essay i want to get things right and do them properly.

    Much appreciated in advance.
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  3. s3reptdi
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    s3reptdi Member

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    [Sep 20, 2013]
    Anyone? Really need to crack on with it! (See what I did there haha)
    #2
  4. Chillout
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    Chillout Active Member

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    [Sep 20, 2013]
    Don't mean to put you under pressure but have you pressure tested it as it could be the oil cooler.
    #3
  5. s3reptdi
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    s3reptdi Member

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    [Sep 20, 2013]
    Yes mate as said pressure tested it and it held pressure, how can it be the oil cooler?
    #4
  6. s3reptdi
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    s3reptdi Member

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  7. tdi-man
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    tdi-man Well-Known Member

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    [Sep 22, 2013]
    I had a c head part number and mine cracked

    get head of and get it checked .

    white smoke is normally water .

    I wasn't losing much water but had cracks between my valves and car ran fine with no problems.
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  8. s3reptdi
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    s3reptdi Member

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    [Sep 26, 2013]
    Thanks for the help guys!?

    Got it the head off and confirmed the worst, heads cracked between all the valves! Where's best place to get a new head that's not going to crack?

    Attached Files:

    #7
  9. s3reptdi
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    s3reptdi Member

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    [Sep 26, 2013]
    Head number

    Attached Files:

    #8
  10. tdi-man
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    tdi-man Well-Known Member

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    [Sep 26, 2013]
    buy new only not recon or second hand
    #9
  11. s3reptdi
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    s3reptdi Member

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    [Sep 26, 2013]
    I will but I don't know where's best to get one from?
    #10
  12. s3reptdi
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    s3reptdi Member

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    [Sep 27, 2013]
    I'm going to send it to the machine shop and get it pressure tested, surely as long as the crack hasn't gone through the valve seats it should be ok?

    Anyone got any advice on this, not getting much response at all!?
    #11
  13. tdi-man
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    tdi-man Well-Known Member

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    [Sep 27, 2013]
    would mess about with reapair m8 just get a new 1
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  14. s3reptdi
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    s3reptdi Member

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    [Sep 27, 2013]
    Not saying a repair, it either hold pressure or doesn't, if it doesn't it's scrap, how much did you pay for a new one? Where did you get it from and have new ones been improved?
    #13
  15. tdi-man
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    tdi-man Well-Known Member

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    [Sep 27, 2013]
    got mine from a local engineering company and used my cams and valves. call audi m8 and price one up think my head was 600 ish


    #14
  16. s3reptdi
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    s3reptdi Member

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    [Sep 30, 2013]
    Audi want about £1200, there's must be loads of people out there that's experienced this, anyone else know where to get one from?
    #15
  17. Sevv
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    Sevv Pushing the limits..

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    [Oct 1, 2013]
    get a used one i know some people pick up non starting s3 engines for 200-400.. just get that polis skim it and use either cams /valves which ever has lower milage and better condition
    #16
  18. tdi-man
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    tdi-man Well-Known Member

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    [Oct 1, 2013]
    #17
  19. Sevv
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    Sevv Pushing the limits..

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    [Oct 1, 2013]
    sorry mate.. i didnt pay attention its a TDI then yeah dont buy a used head it will probably crack again... there is a list complied of which heads are prone to crack vs the ones that dont..try to get them and use the head internals
    #18

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