Cracked cylinder head on old diesel – repair or replace?
My 2007 1.9 TDI Golf has a small crack in the head near one exhaust valve seat (confirmed by pressure test). Overheating history, but runs okay now. Mechanic says new head is expensive- any good aftermarket heads or rebuild options? Thinking of sourcing parts myself to save cash.




Cracked heads on PD TDI engines are unfortunately common from overheating or age, especially around valve seats or pre-chamber area. Rebuilding is possible if crack is small and not through water jacket, but often new or reman heads are safer long-term to avoid repeat failures. I went the parts route for a rebuild on a similar engine- sourced valves, guides, seats, and head bolts separately. Found a solid selection of cylinder head components at https://elartcom.eu/categories/cylinder-head-parts-123 - they carry individual parts like valve guides, valve stem seals, intake/exhaust valves, and even some seat inserts for VW group. Picked hardened seats and new guides that matched OE specs. Head was skimmed, parts pressed in, and reassembled- engine compression even again, no more smoke. Cheaper than full new head and reliable if machine shop does good work. Their category has lots for 1.9 TDI- check compatibility by engine code to get the right sizes.