Engine Rebuilding

July 20, 2003 (update Aug.12, 03)

Well... our 1992 VW GTI 8V with digifant2 engine management was getting tired so we decided it was time for an engine "refreshing".

The following is a how-to article on this subject. Please keep in mind that this is only a general guide and having success depends on the state of your vehicle and your mechanical abilities. This is not a project for an automotive newbie. We are not responsible in any way if you follow this guide and have problems.

In our case the car was blowing oil on cold startup. When not run for a few days it would burn oil for at least 5 minutes. Otherwise it would run ok.

The following guide shows the procedure to remove your cylinder head, prepare the bottom end of the motor and re-install the cylinder head, cam timing. If you spot any mistakes or needed corrections please email me.

We ran into a few snags along the way which will be detailed.

Tools Needed:

Metric wrenches and ratchets, sockets (deep & shallow), elbow attachments, etc.
air impact gun, air wrench, compressor, metric impact sockets.
metric allen key set, particularly 6 & 7mm (both keys and socket attachments.
torque wrench with 15-60ft lbs capacity (1/2 inch drive recommended with 3/8 adapter if required).
assorted screwdrivers.
assorted pliers.
12mm 12-point hex tool (looks similar to torx head for head bolts).
crowbar or prybar
safety glasses.
Varsol or equivalent parts cleaning solvent.
Blue silicone (high temp gasket material) in tube.
bench grinder with wire wheel attachment.
flex or ball hone (sometimes known as rabbit shit hone).
small wire brush.
razor blade(s).
cut-off grinder (if needed).
Never-seize compound or equivalent (copper based).
Digital or conventional camera.
2 jack stands and hydraulic trolley jack.
something to lie on the ground (ground sheet, trolley, foam board, etc) to keep you comfortable under the car.
oil drain pan.
coolant drain container.
electrical tape (black stuff).
paper towels and/or clean rags.
vehicle service manual (Bentley's, Chilton, Haynes, etc) or equivalent CD-rom disc.

Use the camera to take pictures of vacuum lines, electrical connections or placement of components to guide you during reassembly. This is important during disassembly of the exhaust/intake manifolds from the cylinder head and vacuum lines from the air box to the throttle body.

Parts Required**:

valve cover gasket set
upper engine or cylinder head gasket set includes head gasket, intake and exhaust gaskets, coolant flange gaskets/o-rings
new head bolts (these are stretch bolts and need replacing each time after removal)
4.5L 20W50 or equivalent conventional "dino" oil
oil filter
oil pan gasket
v-belts for alternator, water pump, power steering pump (if old ones need replacing)
intermediate shaft seal
timing belt
piston rings and rod bearings (choose bearings with oil holes) - standard size - assuming your engine has never been apart.
4L of VW approved, phosphor-free antifreeze
jug of distilled water
o-rings for fuel injectors (1 ring each injector where it seals into cylinder head)
parts necessary for head rebuild (supplied by machine shop - new exhaust valves and exhaust valve guides, replacement of rusted/missing/damaged studs, valve lifters, etc.
distributor cap, plug wires, spark plugs (if old parts look worn).

Procedure:

pull the hand brake and chock the rear wheels of the vehicle. Raise it with the hydraulic jack in the front and place jack stands up front, then remove the hydraulic jack.
use 17mm deep impact socket and air impact gun and remove front wheel lug nuts and wheels, driver's side optional. Passenger side front wheel mandatory to be removed.
place oil drain pan under vehicle and loosen and remove oil drain plug. Drain oil. Remove old oil filter and wipe gasket surface on engine.
place suitable drain container such as a larger rubbermaid bin under front of vehicle and use pliers to loosen and slide lower radiator hose off it's spigot at the water pump and drain coolant into container.
disconnect positive lead of battery.
remove the coolant hoses and flanges from the cylinder head on the front and driver's side of cylinder head by removing 10mm bolts. Catch coolant in bin under vehicle.

EDIT: more to follow very soon including tons of pictures. Please bear with me... been very darn busy with work lately!! Doh. My apologies to those waiting for this article.