Finally pics of the damage

Ok so many of you have been helping me with the 91 TSi AWD I recently got. I have a few threads on diffrent things pertaining to it.

Today was the day, I finally got the head torn off with alot of help from my dad. I dont really know what to make of the damage yet but here is what I found. Sorry some of the pics are a bit fuzzy, camera isnt the best. Let me know what you guys think?

IF SOME OF THE IMAGES COME UP AS A LITTLE AD FOR PICS FARM JUST CLICK THEM AND IT WILL TAKE YOU TO THE IMAGES.

http://pixfarm.net/upload/1/thumbs/1b/1beb92b8192c761c03044dded8b97163.jpg (http://pixfarm.net/upload/1/originals/1b/1beb92b8192c761c03044dded8b97163.html)


http://pixfarm.net/upload/1/thumbs/18/189ea620a33555ce1493bb58a3dc17f3.jpg (http://pixfarm.net/upload/1/originals/18/189ea620a33555ce1493bb58a3dc17f3.html)


http://pixfarm.net/upload/2/thumbs/13/13a5e42af592ea4f4da6593148c0e8a2.jpg (http://pixfarm.net/upload/2/originals/13/13a5e42af592ea4f4da6593148c0e8a2.html)


http://pixfarm.net/upload/1/thumbs/4c/4c966dbaf61a53ec9d6de86a905d2952.jpg (http://pixfarm.net/upload/1/originals/4c/4c966dbaf61a53ec9d6de86a905d2952.html)


http://pixfarm.net/upload/1/thumbs/eb/eb3d124afdfccdd362a66d2e2c0c5e84.jpg (http://pixfarm.net/upload/1/originals/eb/eb3d124afdfccdd362a66d2e2c0c5e84.html)

that one cylinder must be fucked up, so how did the valve end up in there? did the spring break or something? i think it's time for rebuild but it might depend on how much damage it made, when i bent a valves i was still able to use my bottom end.

Ya that's some issues. You're going to need bottom end work with that damage on the cylinder wall like that. Do any of the other valves look damaged too or just the one?

the other valves seem ok. I am going to take a better lookat them with my dad tonite or tommarow so I will know more then. I am going to clean the cylinder soon and see how it looks.

Any ideas the cheapest way to get it fixed and running again. Dont really want a race car, just want it to run and be able to have a little fun with it. Its a auto btw, not my choice just the way the car was.

probably just get a used one, you can find them for like arround 600-800. i got lucky and i bought my 7bolt for $150.

Owning a DSM seems to be a deathwish lately, your #3 in the last 2 months. Its a good thing you walked away tho, that sounded like a pretty bad crash.

I don't think that block is repairable, it looks like too much damage for even a 60 overbore, the head itself looks alright though. You could probably get away with finding a decent shortblock and slapping your head on it (with some new valves of course) and tossing that in your car.

lol I didnt crash the car??? I think you ment to post in that guys thread whos in the hospital.

I bought my car this way and the body and stuff is completly fine, just that dropped valve.

The damage you see in the pics looks to be at the top of cylinder 1 but really that bent up piece is the head gasket, very lucky. The cylinder hole itself seems to have survived with very little damage.

I will get it cleaned out tommarow and the HG off it then get some new pics. I think the block is saveable but we will see.

If I do have to swap out blocks whats the cheapest I am going to get away with this. Like I said, I just want it to run and drive ok. Dosent need to tear ass everywhere.

Thanks for the help guys.

OK guys. I finally got the piston nice and cleaned out.

In one of the pics (last one I think) you can see the top of the cylinder where there is a lip bent outwards. This was my biggest fear but I got VERY lucky and its only the head gasket! Once I pulled the old gasket the top of the cylinder is virtually untouched!!! =)

The rust on the side of the piston was just barely surface rust, I think from where the HG blew and a bit of collant set in the motor for a year and a half before I came along.

I had some VERY VERY fine sand paper (couldnt actually tell it was sand paper, looked like a black sheet of paper) and I cleaned away all the rust and dirt easily.

So I think my block may be ok. At worst I think I could lose a bit of compression on that cylinder but its not going to be a race car so I dont want to rebuild the block unless I have to.

The piston isnt cracked or anything which is good. However there is a bit of a indintation in the top of it (dosent touch the sides of the cyilinder) Dont bash on me, but what are the chances that piston is still usable. Looks to me like the valve fell in and he bumped the starter once. The valve was forced up in the center of the piston and hit the spark plug.

Like I said the only damage to that piston is a little indintation about 1/2 to 1/4 the diamiter of a valve and that damage DOES NOT touch the outside of the piston where it meets the cylinder.

If you decide to reuse the piston make sure you file down any sharp edges. I got my car with 8 bent valves and never touched the block.

If you are just looking to get it running, I would just buy a used long block. You could find one for not that much.

I wouldn't just half ass it either and put iffy parts in there, it may end up costing you more in the end. You should just shell out the cash and do it right the first time, especially with these cars.

Yea it wouldn't cost you that much more to rebuilt it stock and have it bored out some. Then that thing would last another 150k. Its worth it IMO

hmmmm. I looked into the price of some of this shit. Please keep in mind I live in a TINY hick town.


I looked a set of pistons and rods, the cheapest I can get around here is $250 for the set. There is only 1 machine shop in town (45 miles) and they are a local owned hick shop. They did my brothers ball joints on his 79 F150 Custom, screwed them up 4 times before they had to order new ones and he waited 2 days.

They didnt charge him for that job but its not so easy for me to get the motor rebuilt again if they fuck it up.


The cylinder walls seem to be ok on my block minus my old HG which is gone now. The piston itself dosent appear to have any damage other then the impression in the top near center of it of a half circle where the valve was.

I was hoping to clean the top of the piston up as is and just put it back togather with new valves.

I have never yanked a block, installed a block, or actually rebuilt one. And with the damn priceing and crappy labor around here :(

How much do you think a junk yard would charge me for just a 4G63 Turbo block? Thats assuming I can find one, DSMS are VERY VERY rare around here and turbo ones are virtually never seen. I would prefer a 6 bolt as it was, so that means I need a 90-94 Turbo Block?

A non turbo 4G63 block will work also after swapping out internals.