Pulling my hair out!! (and there's scarce any left) Darn TD5

**Slunnie** · 18th January 2009, 10:48 AM

Originally Posted by revor

Well the head's off..

It ain't pretty... Seems somewhere along the line a Stud and nut of the 6MM variety had gotten into #2 cylinder. It was in the intake manifold when I found it.
Subsequently said stud would hold the #2 intake valve open occasionally, apparently the running rough bit. The valve is bent and the seat gone.

Surprisingly the piston isn't horrible and the bore is fine.

#'s 1,2 3 and four had nice clean pistons, #5 being the only nice, dry and carboned up piston of the bunch. Indicating a failed head gasket across four cylinders. Funny #5 was the only intake port behaving normally.

Where the stud/nut came from is anyones guess. I don't use them and don't think I removed any from the engine when I got it. Might have happened at the wrecker when they dismantled it..

So off to buy a new head.... and double check the bottom end.

Any suggestions on a good source?

You've all been of great assistance and support! Cheers to all! Hopefully it's been at least an entertaining if not educating thread.

Thats a real bugger Keith but good that you've found the problem. Who would have guessed! I imagine that you'll have to import a head??? You can get them from dismantlers in Aus, but would it possibly be cheaper from the UK?

**justinc** · 18th January 2009, 03:36 PM

Who would've guessed?? What a nightmare!!!
If I can help with parts sourcing etc Keith, PM away!

But as Simon said, I reckon EX UK is a cheaper and faster solution.

The Psimpson7 Td5 head removal and refit tutorial is a great guide!

JC

McDisco · 18th January 2009, 04:00 PM

Just as a side and Im not sure whether you have been asked this already, but where did you get the Td5 from? I didnt think they were imported into the States. Did you import yours?

Angus

**revor** · 18th January 2009, 04:40 PM

I will say that Mr. Simpson's detailed instructions help quite a bit! Many thanks for that!!!!

Yes it is a relief to get to the bottom of this mystery. A big ass chain reaction the way I see it.

The motor is a spring (up in this hemisphere) 2001 engine with 40,000 miles on it imported from the UK.
Having the fastener in the intake from the beginning almost makes sense if you figure that it could have sat there on a road going car for months if not years without plopping into the head. The car was finnished and running just a month prior to a big off road we go to each year. During this rally the engine might have been subjected to sidehills and such that might move the offending piece into the head.. In any case the motor needs a fix.

A new head will be coming from somewhere soon. But I like to shop around and while I'm not partial to where it comes from I am partial to feedback about a potential supplier from people I trust. So if you have thoughts about a supplier you guys feel right about I'll look him up.

RoverMan · 18th January 2009, 05:45 PM

Hey Keith,

I had a similar issue before xmas with my TD5 Auto, it would hit 2500 RPM and then loss total power and white smoke would come from the exhaust followed by black smoke.

It ended up being the the hose between the Turbo and intercooler was sucking in also there was a blockage in the intake to the intercooler. Once this was flushed and I replaced the hose it was all good.

Jake

**Psimpson7** · 18th January 2009, 10:15 PM

Hi Keith,

What a nightamre, but at least you have found a proper fault.

Good luck with fixing it!

Rgds
Pete.

**nomadickiwi** · 19th January 2009, 02:37 AM

Hi Keith,
Glad you found the prob. I am in the U.K if you like I can price a head for you. Is the old head beyond repair? If only damaged valve and seat also possibly guide it would be cheaper to fix.My local reconditioner are very professional, so I could ask them for parts to repair if you like.Did it have plastic locating dowels for the head, or the steel ones?
P.M me if I can help at all
Al

**revor** · 19th January 2009, 04:55 AM

The offending bit...

seems it also got into #3 for a little while as well. Today I'll spens some time looking in detail at the head to see if there is hope and the #2 piston to see about damage to it.

You can see by the pic that the valve/pison combo make a fine forging press. That's why the seat is probably unrepairable, but we'll look to be sure.

After having a closer look, our friend the stud was bouncing around from port to port, my guess is once the damage was done in one port it would get blown back out into the intake and go down another.

From left to right intake valves 1,2,3,4,5. Only 1 and five are straight..

**revor** · 26th January 2009, 11:12 AM

Well it' back to running. I got a new head from Turner Engineering in the UK with all the goodies to put it back together shipped three day for a bit over $1600 (USD) a fair deal it seems.
Tossed the head on per Psimpson and the Rave cd, purged the fuel rail with a bit of wire jumpering the fuel pump relay.

I cranked it without connecting the injectors and inspected for oil pressure.

Seemed good so I plugged in the injector harness crossed my fingers and gave it a go.

It fired in two cranks, filled the shop with smoke and tryed to kill me! I guess it's back to normal!

After montoring everything I could and bleeding the coolant system (there's going to be changes here!) I her out for a spin.

She runs right out, perhaps better than before, maybe not, in any case I'm happy it's moving under it's own.

And the wife has promised to not stick any more bolts in the intake manifold!

Once again I'd like to say thanks for all the help and support guys!!

**George130** · 26th January 2009, 07:49 PM

Yay!

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