What is the most likely cause of black plastic debris in the engine of a 93 vw cabriolet.?
Working on a vw I gave to my brother. Was great to me, problem after problem since I gave it to him. Just replaced the coolant hose flange that was totally destroyed. We feared he drove it too long with smoke pouring out, but replace the part and were happy that it started right up and looked good at first.
about 10 minutes into test drive, I notice lack of responsiveness from the engine and a weird smell (burning plastic?).
We pulled into my driveway, opened up the Oil fill cap and by shining a light down there we could see a chunk of melted black plastic and pulled it out with some pliers. It looks like there is another peice in there that wont come out so easily. it looks like it could be part of the old coolant flange, but it seems like more plastic than is missing from the old part.
Any idea what that is or time for exploratory surgery? I'm gonna end up taking off the head and replacing the head gasket now huh?
That is the Oil Splash Guard.
You have to remove the valve cover to totally remove it. If the Engine got hot enough to melt that then you have some issues to deal with.
You have probably warped the head and need to remove it to have it measured and milled square. And may have floated a valve.
You will need to replace the head gasket.
You will need a new valve cover gasket, may I suggest that you buy the upgraded version from www.germanautoparts.com The upgraded versions have new shoulder studs that replace the shouldered ones that are there.
The new gasket is one piece. verses3 pieces for the old standard.
Do not over torque the nuts as they only take 17 inch pounds.
And you will need a new oil splash guard. They started installing that in 84 on all cars as if you forgot to replace the oil cap you would run out of oil in a short time.
Since you are doing so much work, I would also suggest that you replace the oil pump with the upgraded version too.
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