Seized engine help [emoji30]

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GregWalters
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Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

Hi guys,
Long post ahead, thanks in advance for any help!

Bought a caddy recently with engine problem, oil level rising with fuel
So I instantly replaced tandem pump internal seals and fresh oil, drove locally for around an hour total and oil level didn’t rise, so I thought it may have fixed the issue.
Used it for work this weekend and the oil level had risen once I got there.
So I ordered injector seal kit which had since arrived at home.
Drove home from work and engine seized on the way home. Frustrated is an understatement.

It was a little smokey but assumed that was injector seals, just wanted to get it home so I could change them! Unfortunately had music on and it was dark so couldn’t hear any noises when it cut out, or see and smoke etc either. No lights came on, it just slowly dropped rpm and wouldn’t respond to throttle and cut out, coasted and pulled over and it wouldn’t crank.
Checked codes as had Carista with me, got P1267 PD unit injector cyl 3 (n242) regulation range exceeded. Not sure if that was the cause or if that was from the drive up to work.
Then got recovered.
Cam belt and tensioner was done 15k miles ago

So I’ve been on the strip down today.
No holes in the block/oil leaking anywhere
Removed glow plugs, can’t turn engine by hand from the cam bolt. Oil on glow plug 1 and 3?
Removed valve cover, cam looks a little worn, will upload pictures, but to my understanding wouldn’t cause engine to seize.
Removed injectors as need to do the seals anyway if eventually gets fixed
Still can’t turn engine by hand clockwise or anti-clockwise.

Checked inside with a cheap borescope and can’t see much wrong, again will upload video

Checked fuel filter and no oil in there

My assumption is injector seals failed badly and hydrolocked engine with fuel and have bent a rod.
My next step will be to remove sump and try and see any damage from below.

Turbo is new, boost hoses not filled with oil, just a small amount, will upload photo is that normal amount of oil in boost hoses? Was the same amount before the engine seized also.

Another new thing I’ve spotted is the oil filler cap was slightly creamed up and also in the pcv pipe, but not major.

Think I’ve covered everything,
Any ideas?
Thanks ImageImage


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Last edited by GregWalters on Tue Jan 09, 2024 3:22 pm, edited 3 times in total.
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GregWalters
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Posts: 77
Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

Sorry for pictures spam but can only post one at a time:
Oil in boost pipe, normal or excessive? Turbo is new
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Last edited by GregWalters on Tue Jan 09, 2024 3:23 pm, edited 1 time in total.
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GregWalters
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Posts: 77
Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Re: Seized engine help [emoji30]

Post by GregWalters »

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GregWalters
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Posts: 77
Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Re: Seized engine help [emoji30]

Post by GregWalters »

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GregWalters
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Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

Cam wear?

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Last edited by GregWalters on Tue Jan 09, 2024 3:24 pm, edited 1 time in total.
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GregWalters
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Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Re: Seized engine help [emoji30]

Post by GregWalters »

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GregWalters
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Posts: 77
Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

The wear on the flat surface where the injector sits here concerns me
Edit: from looking at the injector surface I think it’s just where someone has pry’d the injector out previously

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Last edited by GregWalters on Tue Jan 09, 2024 3:24 pm, edited 1 time in total.
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GregWalters
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Posts: 77
Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

Small amount of creamy oil in pcv pipe since/when engine failed, wasn’t there before

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Last edited by GregWalters on Tue Jan 09, 2024 3:25 pm, edited 1 time in total.
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GregWalters
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Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

Carbon build up on injector tips?
Injector 1 bottom red oring has visible damage/flat spot

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GregWalters
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Posts: 77
Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Re: Seized engine help [emoji30]

Post by GregWalters »

Borescope video, sorry for rubbish quality Image

https://youtu.be/ETMc1K0bUmc?si=wuIEelQvYmQmx3HQ


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GregWalters
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Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

Edit: deleted


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Last edited by GregWalters on Tue Jan 09, 2024 11:50 pm, edited 1 time in total.
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GregWalters
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Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

Took sump off yesterday, fair bit of metal shavings in sump, considering I had emptied and cleaned sump and fresh oil 120miles before the seize
Taken head off today
Can’t see any damage from the top in regards to piston hitting valves/cylinder damage

Only damage signs are worn cam, worn lifters, metal in sump
Still can’t turn crank by hand
Am I missing something obvious? Or has it got to be a bent rod or seized crank bearing somehow?


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Last edited by GregWalters on Thu Jan 11, 2024 4:07 pm, edited 1 time in total.
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GregWalters
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Posts: 77
Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Seized engine help [emoji30]

Post by GregWalters »

Cam bearings very worn, camshaft very worn, a few of the lifter heads damaged/dented
Assuming the crank bearing are similar and have caused it to seize

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GregWalters
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Posts: 77
Joined: Mon Oct 30, 2023 2:27 pm
Engine size/power: 2.0 TDI (140bhp)

Re: Seized engine help [emoji30]

Post by GregWalters »

If crank/main bearings have caused the seize, could it be a case of replacing bearings 1 by 1 and then could be usable? (And then new cam+followers)

Going to be doing more investigation tomorrow if anyone has any ideas


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PeterAFox
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Engine size/power: 1.9 TDI (104bhp)

Re: Seized engine help [emoji30]

Post by PeterAFox »

cam bearings don't look too bad to me, but now if you rebuild you should replace them ;-)
feel the lobes on your camshaft, if they feel like they're flattened off then probably worth replacing camshaft.
possibly a piston ring has seized/broken (or maybe a big end bearing).
when the cylinder head is off, you should be able to see something. possibly needs a rebore or new engine block or could be something like a piece of valve is jammed somewhere.
You took the sump off - did you look up at the crankshaft, connecting rods and the bearings etc.?
I read that sometimes the connecting rods go, possibly caused by oil not flowing through into the bearings properly or the oil sprayers are blocked / not aligned correctly or just metal fatigue.
some damage around your injector seatings, which if wasn't caused when getting the injectors out, suggests some kind of FOD.

not very nice for you, but if you repair it successfully, you'll have a nice reconditioned engine.BTW: if the head and sump are off, it's not so difficult to replace the big ends, assuming that pistons move / one of them isn't seized by something.

Sometimes I wonder if getting an insurance job engine from ebay is just much easier (and cheaper) than a full rebuild, especially that the front bumper comes off so one can get the engine out.
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