Could be the head gasket. Did the head rebuilder check the head for cracks?
How about the thicker head gasket? or is it a stacked set of gaskets?

You could do a leak down test to figure out which cylinder it'd coming from

Also, on a Diesel, you don't worry about lowering the compression for running
higher turbo boost, the more the better, some tractor pulling diesels run compound
turbocharger systems boosting the engine by as much as 100 PSI    this also
adds quite a bit of power as well, the advantage of too much air in a Diesel engine
is that the exhaust gas temps go down, and burning all of the fuel instead of
leaving black smoke clouds

I dont think its a head gasket. its new oem metal one with apr head studs and a rebuilt head. I got my turbo back (another wasted 500 bucks) put it on and went for a longer drive. its still screwed. too bad cuz' it runs awesome!

anyways enjoy the pics.

And the head stud torque is correct, does the spec change with the studs?

I was also wondering if the studs were too long and were bottoming on the
shoulders of the studs before clamping the head properly.

How about the intake manifold? is there any coolant running thru it?

And the head stud torque is correct, does the spec change with the studs?

I was also wondering if the studs were too long and were bottoming on the
shoulders of the studs before clamping the head properly.

How about the intake manifold? is there any coolant running thru it?

the studs are correct for the engine and torque double checked (but I will check them again tomorrow) it is doing exactly the same thing as before thats why I tore it down. and I did not find a obvious "blow" on the old gasket which makes sense now. and the manifold is dry.

Could be the head gasket. Did the head rebuilder check the head for cracks?

You could do a leak down test to figure out which cylinder it'd coming from

Also, on a Diesel, you don't worry about lowering the compression for running
higher turbo boost, the more the better, some tractor pulling diesels run compound
turbocharger systems boosting the engine by as much as 100 PSI    this also
adds quite a bit of power as well, the advantage of too much air in a Diesel engine
is that the exhaust gas temps go down, and burning all of the fuel instead of
leaving black smoke clouds

also on this. the AAZ motor is a indirect injection motor so it cannot take boost like a direct inj motor like you talk about here
How about the thicker head gasket? or is it a stacked set of gaskets?
 its just one head gasket 

After reading through here, Jluck, I can definately see why you are not happy with your T/D setup. I hope that you get it figured out soon, and for good.

I was just looking into your problem, seems the heads are prone to cracking
but the block cracks are around the bolt holes in the block and it causes oil
to leak into the coolant.

The cracks that are common in the head are usually between the valves, and
that the heads are junk once overheated and warped, warpage limits are very
tight.

The head gaskets come in different thicknesses to compensate for the piston
popping out of the top of the block, and are supposed to be matched with
the same gasket, 1,2,3 holes or notches, I don't know if it's a different gasket
or just a different thickness on the notch gaskets.

The common cause of exhaust in the coolant is a warped head or gaskets not
sealing, and there is a special gasket adhesive that is supposed to be used and
is a must according to what I have read.

Hope this is your problem and not a junk motor, did you use the sealant on the
head gasket?

Wild

I did it as instructed by my local vw diesel guru. (no sealant other than what comes on it) the head was checked and rebuilt too. I just dont know.....I will torque it down again (maybe tonight) once the sobbing stops. :'(

thanks for the help wild, I think I have spent as much time on it as I'm going too. its time for plan b or c or d wherever I am now. maybe back to zuk power?? maybe cut my losses. just don't know.

I did go out and check torque and went up five pounds but no changes. still screwed. thanks again.

FOR SALE.

FOR SALE.

sad when a build thread ends with FOR SALE 
sorry your having so much trouble, but is now the time to turn back, or kick it's ass?

Oh dude... I just read through this... I'm bummed for you, seriously...

Let's find a block.... Don't sell it yet.

-Eric

Oh dude... I just read through this... I'm bummed for you, seriously...

Let's find a block.... Don't sell it yet.

-Eric

Seriously, im with Eric !

thanks for the encouraging words guys but I think this kick has officially ran me out of curse words. I will take some time to think on it.

thanks for the encouraging words guys but I think this kick has officially ran me out of curse words. I will take some time to think on it.

Good.... just take at least the Holiday break off and then consider what to do..

-Eric