Date:         Wed, 10 Dec 1997 13:08:40 -0800
Reply-To:     Ray Hunnam <hunnam@PNC.COM.AU>
Sender:       Vanagon mailing list <Vanagon@Gerry.SDSC.EDU>
From:         Ray Hunnam <hunnam@PNC.COM.AU>
Organization: RAYJEN Security
Subject:      pistons shatter 91 wasterboxer
Content-Type: text/plain; charset=us-ascii

Writing to the list to share my experience when the
pistons in my 91 Vanagon 2.1 ltr decided to give up the
ghost.

I bought my Van second hand with 90kms on the clock.
Had it inspected by the local automotive association
(NRMA) in Australia who gave it a clean bill of
health.  Went well for for the warranty period then I
started to hear funny noises coming from the
crankcase.  Also developed a water leak from, guess
where ?.  Had this inspected by the dealer who
discovered the dreaded cracked head.  The dealer had
the heads repaired by welding.  This action proved
worthless as the head problem was not fixed.  In the
end the dealer replaced the two heads with
reconditioned ones.  I must say the dealer was good
enough to carry out the work under warranty even though
it had just expired.  All went well for a time but
could still head the noises coming from the block.

All through the head problem period I never let the
water drop.  Even went to the trouble of carrying a 3
ltr coke bottle (minus coke of course) filled with the
coolant mixture and when I stopped I would top up the
refill tank.

More of the noises.  Had the van oil changed at 5000 km
with a good quality product (Shell Helix) and never
noticed any gunk or whatever coming out or in the
filter.   Still hearing noises.  Talking to the Service
Manager at the dealer he came up with some
possibilities including gudgeon pin walking, broken con
rods as well as other possibilities.  He advised to
strip down and see and rebuild the original engine.  I
was still driving while all this was going on.  I know
some of the fellow listers will shout horror and hang
the bast@#* but this is the daily driver and with three
kids we need the D.D.  The noise was not getting any
louder so I guessed I had a bit of time up my sleeve to
save a bit of money for the task.

Let me liken the noise to someone with a handful of
pebbles shaking them in a can.   The sounds would only
come when backing off the go peddle.  Never hear it
under load or when accelerating.

Ok to end this saga.  The Service Manager and his band
of Merry Men dropped the motor and split the case.  We
found that three of the pistons at the bottom of the
skirts had kaputed.  They broke into little fragments
similar to shrapnel and these were rolling around
inside the case, hence the sound like pebbles inside a
can.  Luckily they did not cause any damage to the
internals, I must be blessed !  The service manager and
his boys went over every inch of the case and could not
find anything.  The area which shattered could be best
described as the packing around the gudgeon pin and
extended down to the skirt or side walls, all below the
level of the rings.  I kept these for future reference
and curiosity.  They have been shown to various local
mechanics including one friend who did his training on
VW.  All agree they have never seen anything like it.
I kept the cylinder sleeves also they all show various
signs of gudgeon walk i.e. the pin moving across and
scoring side of the sleeve.  I also kept the shrapnel
bits.

Right what caused this.  The engine builders could not
find any incidence of cooking the motor or other shoddy
servicing.  The damage has been caused to the bottom
end of the pistons.  Maybe those gudgeon pins walking
may have started it off.

Here I pose the ultimate riddle.  Any ideas.  There is
a moral to this tale -  If you hear a noise listen to
it.

Ray Hunnam

P>S> since the engine rebuild guess what head trouble.
When rebuilding the engine I, like a fool did not
replace the head.  Next time I will be purchasing two
from The Bus Depot and freighting them over to Oz.
Believe it they will be cheaper from Ron than getting
them from VW Australia.