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Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Power Enhancements

TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old March 18th, 2010, 12:59   #1
russ_tdi
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Default PD Melted piston

hello all
Iv got a pd130 with 17/22 turbo WI and all the norm bits to go with it. Was making 268bhp and 412lbft for over 2 years (22k miles) up untill a couple of weeks ago. Was going along at 85mph when it started running on three. so did the norm compression check and no4 was down, so thort head gaskit. when i ripped the head off i found that no4 piston has what i can only describe as melted the top on one side it has got very hot and saged. found no damage to rings or bore

Anyone had this or any ideas what it could be corsed by? was thinking if my injectors spray pattern was very bad it would only cool some parts of the piston with the fuel duse this sound right?

thanks
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Old March 18th, 2010, 13:10   #2
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Quote:
Originally Posted by russ_tdi
hello all
Iv got a pd130 with 17/22 turbo WI and all the norm bits to go with it. Was making 268bhp and 412lbft for over 2 years (22k miles) up untill a couple of weeks ago. Was going along at 85mph when it started running on three. so did the norm compression check and no4 was down, so thort head gaskit. when i ripped the head off i found that no4 piston has what i can only describe as melted the top on one side it has got very hot and saged. found no damage to rings or bore

Anyone had this or any ideas what it could be corsed by? was thinking if my injectors spray pattern was very bad it would only cool some parts of the piston with the fuel duse this sound right?

thanks
Perhaps it was a leaky injector causing preignition or it streamed...
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Old March 18th, 2010, 13:29   #3
silver_tdi
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I would guess it would be your injector spray pattern. They operate at extremely high pressure. I have seen diesel injectors on C15 Cat's blow a hole right through a piston. Your PD injector runs at a higher psi than the Caterpillar engine does about 2050 bar or 29 750 PSI according to this source. http://www.langleyvw.ca/tech/pd.html
So even if your spray pattern was off just a bit it would make the top of the piston look almost melted. Is the point completely gone off of the top of the piston where the injector sprays if it is, that would be a good sign of improper spray pattern.
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Old March 18th, 2010, 14:08   #4
hatemi
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I just wonder it lasted so long with the claimed turbo and powerlevel. EMP->EGT->Molten engine.
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Old March 18th, 2010, 14:13   #5
tdi_davy
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With this turbo i would not go higher then 215hp....
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Old March 18th, 2010, 14:53   #6
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Quote:
Originally Posted by hatemi
I just wonder it lasted so long with the claimed turbo and powerlevel. EMP->EGT->Molten engine.
I don't even think that power level is even remotely possible with the hardware given, but with all of the dynos out there that defy logic and mathmatics you just have to give up.
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Old March 18th, 2010, 15:09   #7
ArturCosta
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Quote:
Originally Posted by hatemi
I just wonder it lasted so long with the claimed turbo and powerlevel. EMP->EGT->Molten engine.
x2

Maybe it was never pushed hard for a long time... and when it was cabum.

I also own a melted piston in my garage

Back to topic , maybe the high PCP and EGTs where the reason the piston melted.
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Old March 18th, 2010, 16:55   #8
russ_tdi
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cheers for the quick replys and input

I did find it wird that it was making that much power. I just thort it was a fluke as i was told the turbo had bin built a wee bit difrontly from the norm

iv had it on 4 diffront rolling roads came out as 259.8, 262.3, 265.1 and 268.2 so just went with it

Running at such a push i always thort something was going to give but i thort it would be the turbo 1st

now im re building it and going a step up with head work, race injectors and a bigger turbo i would love to get to the bottom of the problem so i can stop it from going agen

will try and get pics up asap. Think it will help a lot more than me trying to explane
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Old March 18th, 2010, 17:01   #9
DanG144
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Verify that your piston oil squirters are all good and clear, and aimed correctly.

This sounds as if it could be a contributor.

Dan
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Old March 18th, 2010, 17:09   #10
russ_tdi
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one of the good pistons looks very sooted up



the bad one no4

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Old March 18th, 2010, 19:16   #11
The Shootist
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Be sure to check that injector. The melted spots match the spray pattern.

The sooted piston has a pattern that stretches a ways out onto the piston crown. I'm not that familiar with what that pattern normally looks like, but a deviation in timing could be an issue too.
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Old March 18th, 2010, 21:08   #12
ocshaman
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In your first post you mention WI, would that be water injection?
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Old March 19th, 2010, 00:28   #13
russ_tdi
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yes running a water injection as well
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Old March 19th, 2010, 09:54   #14
mojogoes
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Quote:
Originally Posted by russ_tdi
yes running a water injection as well
Was/is that water only or W/M mix?
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Old March 19th, 2010, 11:58   #15
russ_tdi
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water meth with a 40-60 mix. 40 meth 60 water
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