2001 T4 2.5tdi

...purchased through a fellow FDK'er as a non runner, work began as soon as we got it back from Cheltenham to Leicester





safely back, time to trip down the top end and assess the damage...





amazing how quickly everything comes apart!

The verdict... 5 bent valves in the head and 2 damaged pistons (you can see where the valve has hit the piston crown).A 3rd has been 'kissed' but I don't think needs replacing





next step, have the head re-built, swap the pistons and get it running!

Soon be back on the road!Keep up the good work bro!

3 used pistons off ebay, £120... getting there, slowly

The wonders of ebay

managed to haggle the pistons down to £100

stripped the manifolds, turbo etc off the head last night ready to take to the refurb place. Took a few photos to show the bent valves...

Is it just valves or are the guides gone too ?

I can't tell yet with the valves, cam etc still in. I'm gonna take the head up to a refurb place in Nuneaton and they'll check everything over but I'm inclined to get the guides done anyway while it's with them

Might aswell it would be a proper ball ache to have them fail after

yep, well no. 3 valve has seized in the guide (I can't even get the lifter out) so all new guides it is. I think they'd replace them all anyway in the rebuild.

Picked up the replacement pistons on Friday from a nice Polish chap in Redditch. He's broken a few T4s so if anyone needs bits, I'd recommend him



we only need no.s 1 & 4 so I've stuck no. 2 back on ebay to try & make some cash back

http://www.ebay.co.uk/itm/VW-Transporter-T4-TDi-2-5-Piston-1or2-ACV-AJT-/220875101371?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item336d2e94bb#ht_500wt_1413

Had the call from Cylinder Rebores in Nuneaton, 8 new valves and 3 guides, £184... I thought it'd be nearer £300

Hopefully we can start the re-assembly over the weekend

Really please with the results

Would have had the engine finished on Saturday if we weren't missing some gaskets Should be running next Saturday now

For anyone interested, here's what the parts have cost...

2 x used Pistons £65 (bought 3 for £100 & sold the spare on ebay for £35)
Head Reconditioned £184
Cam Belt Kit £108
Water Pump £23
Head Gasket £68
Hydraulic Lifters £70
Manifold Gasket £7
Oil £16

So just under £500 in parts. I'm pleasantly surprised by that!

Running again

Nice one Ben