Rebuild!

[DPJ]

.....Anyone know where to get these 'Bentley' manuals I hear about on Vortex?

Clicky

Haynes Mk4 Golf is good for what you want, imo.

 

[DaNnY_LaD]

Alright rob..

i found a place local to me which would Pressure Test,Skim,New valve seat,Re-lap,New Valve and camshaft seals Then Rebuilt back up for £125.12 Inc Vat

So Dropping it off on saturday...

 

[RobDon]

Wow, amazing price, where was that?

I got the head off today, here's some pics:

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd1.jpg
http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd2.jpg

Check out cylinder No.4!

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd3.jpg
http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd4.jpg

Head disassembled ready for exchange:

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd5.jpg

I have decided that I AM going to do rods at this time, not much extra work involved in getting the sump off and removing the rods etc. so would be foolish not to do it now.

I'll decide on new rings, honing etc. once I get the pistons out and see what the bores and rings are like - whether they need doing or not.

 

[Willie]

Well at least you have found positive signs of a problem.
Nothing worse than removing everything and not finding anything.

Seems like the right idea to do the rods as well. Alot of extra cost but once its done, its done

 

[RobDon]

Yes indeed, definately alot of oil coming through on No.4 and signs of slight leaks on No.1 and 3 as well. With the amount of work required to get the head off, doing the sump etc. will actually be pretty easy - the timing belt area is just a total nightmare to work on!

Just ordered a set of IE 19mm rods and OE rod bearings direct from IE - £282 including express shipping, so should have them next week. (still cheaper than buying them in the UK!)

 

[Willie]

Ats good Rob, if nothing else you will understand a bit more about your car.

Hope all goes well.

 

[DaNnY_LaD]

Wow, amazing price, where was that?

I got the head off today, here's some pics:

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd1.jpg
http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd2.jpg

Check out cylinder No.4!

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd3.jpg
http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd4.jpg

Head disassembled ready for exchange:

http://i312.photobucket.com/albums/ll330/SonicBlueLeon/hd5.jpg

I have decided that I AM going to do rods at this time, not much extra work involved in getting the sump off and removing the rods etc. so would be foolish not to do it now.

I'll decide on new rings, honing etc. once I get the pistons out and see what the bores and rings are like - whether they need doing or not.

Yeah i thought that....

It seems i rang out 5 places and compared Prices and then they offered a ''CASH'' price Which was the Lowest ....

As your doing the rods dont forget the torco Engine assemble lube as this is what ul Need...at 40k miles i dont thing you'l need to re-ring it and hone it....

You should have a nice Criss cross pattern on the cylinder walls..You don't want it to be Uber smooth and shiny...Glazed..
The Bit for the ARP 2000 Bolts on your new rods are a 11mm 12 multi point socket....

Also Double check everything when doing it...took me 8hrs to build up my bottom end due to keeping it clean and Triple checking everything...

For a bottom end Rebuild you'l need:

Ball multi Alan key Set(Sump)
Piston Ring Compressor
11mm Rod Socket.
Torco Lube
Decent torque Wrench

 

[RobDon]

Yep no worries, I've got all that already. I've rebuilt engines before, but not for a long time and they were Ford engines. I'll do what Bill said and just rub the bores down by hand, clean and lube them then refit the pistons with new rods and bearings.

 

[Willie]

Too slow, lol

 

[RobDon]

Lol, thanks anyway m8, I think I've got everything I need to do the work.

 

[DaNnY_LaD]

Are you going todo the oil pump aswell rob?

there £106.09 from seat & the pick up us around £8 but you could always clean yours out with brake cleaner

 

[RobDon]

Dunno if I need a new one at only 40k miles?

 

[wild willy]

Looking good Rob, watching in admiration. Hope it goes back together a little easier for you. Your in the premier 1.8T modding league now mate.

 

[ibizacupra]

Just ordered a set of IE 19mm rods and OE rod bearings direct from IE - £282 including express shipping, so should have them next week. (still cheaper than buying them in the UK!)

Good news on doing the Rods Rob



will you get hit for duty & vat tho Rob?

 

[RobDon]

Probably Bill, but going on past parcels it should hopefully still work out cheaper than buying rods and bearings from here in the UK.

 

[PhilW]

Good work rob, i done the exact same thing when i started burning oil. I just wish i had done more now like valves.

Cylinder 4 is pretty shitty isnt it. lol.

 

[RobDon]

Well I may just turn this into a longer all winter project and fit valves etc. before next March. The inlet valves are very small and thin, no wonder they break!

New timing belt kit arrived this morning.

 

[csd_19]

Nice work there Rob! Glad to see you're going to do the rods afterall - are you going to stick a new oil pump in as well?

Hmmmm yeah no. 4 deffo looks like the issue lol!

On the valves, I thought it's usually the exhaust ones that let go? With the 2-piece construction?

 

[Willie]

Did you go for the Kevlar timing belt?

 

[RobDon]

Haven't gone for the kevlar belt as yet, I have a new OE kit here at the mo. If it is the exhaust valves that usually fail then I think I'll get a set of one-piece valves and stick them in there too.

http://www.intengineering.com/VW/18T/Valvetrain/18t-20v-Performance-Exhaust-p5384330-1-2.html

If the rods arrive next week I aim to have the bottom end back together within a few days after I get them, then the head back on shortly after that.