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2005 GTI RFI Seized

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vettepilot_6

vettepilot_6

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Had a great day today...ended with a locked engine lol...had to lock my legs around step up and back stroke it back to shore...took about 40mins lol.....pulled plugs and front plug looks like it has water corrosion on it...(salt water) so looks like a rebuild coming up...be ready for some questions as I go along....first thing is to pull the head and check bore I suppose....
 
Damn nobody around to pull you in? That sux! Sorry to hear engine locked. Tear into it and get to work! Season is almost here!!!


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manolocross said:
Damn nobody around to pull you in? That sux! Sorry to hear engine locked. Tear into it and get to work! Season is almost here!!!


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Click to expand...

Season almost finished here..... Australia.... Have just sent a message to a firm that does exchange engines just in case...but Im thinking it will only be top end rebuild (fingers crossed)....

Here is first question can I do a top end rebuild without removing engine block out of hull?
 
I have done rings before with the block still in. So it would be just a matter of changing cylinders as well for you, I don't see any reason why you can't do it n the hull.

That being said, I would never do it that way again, it is a total pain. Working on the bench is much easier and more accurate. You will want to check your oil injection, fuel injectors etc to figure out why that piston blew, all things you can do on a bench much faster.

The time it takes to remove the motor will be saved by being able to work on the bench.......and you can clean the bilge too.

I should add, you need to consider that when re-installing the motor, you should have the alignment tool to line up the engine with the pump properly.

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kicker said:
I have done rings before with the block still in. So it would be just a matter of changing cylinders as well for you, I don't see any reason why you can't do it n the hull.

That being said, I would never do it that way again, it is a total pain. Working on the bench is much easier and more accurate. You will want to check your oil injection, fuel injectors etc to figure out why that piston blew, all things you can do on a bench much faster.

The time it takes to remove the motor will be saved by being able to work on the bench.......and you can clean the bilge too.

I should add, you need to consider that when re-installing the motor, you should have the alignment tool to line up the engine with the pump properly.

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Cheers Kicker...I will pull head first an see what damage has been done...hoping it is gasket failure causing water ingestion...if not after rebuild I will replace injectors and service/rebuild oil pump...but yeah it would be much easier out, was hoping I didnt have to go that far down lol
 
okay pulled head...not a lot of damage so far...but it has ingested something brassy and soft? any ideas what this was once? debris in front cyl.jpgdebris again.jpginside bore.jpgbore again.jpg
 
Washers around big end of connecting rod ?

Butterfly from one of the TB's ?

Nothing else in there of that color that I can think of
 
Mekanix said:
Washers around big end of connecting rod ?

Butterfly from one of the TB's ?

Nothing else in there of that color that I can think of
Click to expand...

No throttle body I dont think? Fuel Injected.... Would a bigend washer get past piston without scoring bore all the way to top? it looks like some sort of black plastic in amongst it also...does bigends have plastic washer as well?
 
You have throttle body's not carburators right? so you have butterfly valves in those throttle body's the same as a carb would.

Big end's sandwitch the connecting rod between two soft washers. and it could have made it up there with all the turbulence and air flow. but being softer than the other two materials in there it would get destroyed first.

Could it be one of the tip's of the injectors?

Or maybe something in the airbox fell through and got sucked in ?

going to have to pull that cylinder and have a look
 
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How? that section is isolated from each cylinder, unless it blew a hole through the casing ?
 
Mekanix said:
How? that section is isolated from each cylinder, unless it blew a hole through the casing ?
Click to expand...

Or if the seal blew out first because the rotary gear was crapping out. It would be a long shot though, the pieces look to big to get through that area.
 
What about the rave valves? but I don't think they are made with copper are they ? I thought it was some sort of aluminum alloy with plating.
and what is that black plastic? seems more like the crank seal now, but that would probably flood the base in no time with all the oil in the thank.
 
Mekanix said:
You have throttle body's not carburators right? so you have butterfly valves in those throttle body's the same as a carb would.

Big end's sandwitch the connecting rod between two soft washers. and it could have made it up there with all the turbulence and air flow. but being softer than the other two materials in there it would get destroyed first.
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Yeah I thought it was a rotary type valve..but no the butterfly still there...thinking bigend washer as I pulled cyl's and bottom end is the culprit...partial seize....so I think I will send my block away for rebuild..as at this stage I have no access to presses etc..sold all my workshop tools with shop...one tiny score in cyl, would probably disappear with a hone...but I also discovered sand in water holes in block (base of cyl) strange because I always start and stop in knee deep water...(would that be there from PO) or do I need to start and stop in deeper water?

Thanks for the replies....Dave
 
knee deep would be the limit. It wouldn't hurt to go a little deeper, . Maybe try flushing a little more often, that reverses the flow of water and will loosen up some of the sand stuck in the corners.
 
kicker said:
knee deep would be the limit. It wouldn't hurt to go a little deeper, . Maybe try flushing a little more often, that reverses the flow of water and will loosen up some of the sand stuck in the corners.
Click to expand...

I flush every time as well as give it a good run before coming in.....maybe I will have to 2nd hose internal seal and flush longer?
 
Sand will be in the water when you stir it up and could get sucked in. I'm always in the habit of pushing the back ski up and down in the water several times to dis-lodge any sand that gathers in the pump when you beach the ski. A good rule of thumb is if it will gather on the ride plate it will be in your pump. Short of putting an inline strainer it's bound to get in there. I've never had a strainer and never had a problem, yes I have found small amounts of sand in the very bottom of cylinders before.
 
I've tried purging the water after a run with the ski all of 6 inches above the water and the thing started a water spout and sucked itself back down the trailer !

It will suck no matter what the depth is. I've also found some debris in my cylinders the last time I rebuilt. I think its just a dead spot that the sand ends up in and clogs up the drain.
 
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here is some more pics...you can see the brass powder all through the front crank section...bores are pretty good...I will get the measured...might be able to go std piston and rings again...also here is a pic of sand in water jacket...debris in front.jpgbore pretty good.jpgsand in water jacket.jpg
 
Pulling the engine today....Looks like I will have to buy an aligning tool lol...might do the impellor and change oil in pump etc...
 
vettepilot_6 said:
Pulling the engine today....Looks like I will have to buy an aligning tool lol...might do the impellor and change oil in pump etc...
Click to expand...

Yup, may as well go through everything and replace anything that looks questionable. Nice time to do the fuel pump and screens. We pick them up at the auto parts store here for a reasonable price.
 
kicker said:
Yup, may as well go through everything and replace anything that looks questionable. Nice time to do the fuel pump and screens. We pick them up at the auto parts store here for a reasonable price.
Click to expand...

So basically strip whole ski lol..... damn this will take all of autumn and winter lol....
 
Ya I guess your just starting the cool down season over there, we are just starting to unthaw at this end of the world. Hopefully you got some good use out of that ski over the summer.
 
Good to hear.

That is one mighty fine beach you go to, its beautiful, where's all the bikinis
 
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