Author Topic: rebuild  (Read 1344 times)

Offline muppet

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rebuild
« on: 10 September 2009, 21:38 »
hi guys... been a while since i last posted but i have been doing a lot of thought into rebuilding an engine

mainly my 1.8 16v

ive searched but havent really found what i needed to know! i really wanted to know is what normally needs to be "rebuilt" about the engine?

parts and everything.. everything and anything that would need replacing! theres not a lot wrong with the engine just burning some oil but im thinking why not do a bit more whilst the heads off!

so all i need if you can is a list of what needs to be done for an engine rebuild on this engine? thanks in advance guys

VW BUSH

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Re: rebuild
« Reply #1 on: 10 September 2009, 21:41 »
Buy an ABF rebuild it on the bench shove it in (like its that simple :grin:)

Offline DarnPB

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Re: rebuild
« Reply #2 on: 10 September 2009, 21:56 »
It depends on what you are after. If you want to restore your power, then TBH, not much will need doing. If you want a new engine then everything will need renewing. Assuming you want to restore lost power, I will base this list on that.

You will need to remove your head and dismantle it, ie, remove cams, tappets, valves and springs. Make a note of what goes in what position, ie which valves came out of which hole, tappets etc. Give the head a very good clean, removing as much of the carbon as you can get out. Do the same with the valves. I do this by fitting the valves into a pillar drill and turning it on slow speed, whilst applying wet and dry to the valve until it comes up shiny. I then check the freeplay of the valve in the valve guide. You probably won't need to change the guides, but it depends on what your goals are.
The head itself will need a skim. I would resurface it only to flatten the surface and not to increase the C/R. I would then just lap the valves back into their seats. You don't need to go too far with this. A thin abraised line is sufficient of decent sealing.

The engine will need dismantling. I would take the crank to a specialist and have it dimensioned to see if it needs a grind. It probably won't so new shells would suffice. Both big end and main end. Also get him to dimension the bores. Again, they will probably be ok, so only new rings would be required. These would need to be gapped and the pistons would need to be well and truly cleaned without being scratched, including the ring grooves.

The parts new I would replace as they are cheap enough would be the tappets, big and main end shells, piston rings, oil pump, head retaing bolts and of course a full engine gasket set.
I did this on my 8v, and it only cost me a couple of hundred quid, plus time.
If I think of anything else I will put it down later. 5 minutes thought on an engine rebuild is not enough! :wink:


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Offline muppet

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Re: rebuild
« Reply #3 on: 10 September 2009, 22:06 »
lol as much as i would love to do an ABF, just to keep my mind at rest i would still end up rebuilding it!!!!

thanks for the info DarnPB, and that is what im after.... just to get lost power back

from what you have said ill see if i can get a pricelist together to see roughly how much it will cost me!!!

i do have another 16v engine my mate has just lying around and said i could have it for a reasonable price! comes with gearbox and if i were going to i think i would rebuild that and then stick that in!

what are your thoughts?

Offline DarnPB

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Re: rebuild
« Reply #4 on: 10 September 2009, 22:28 »
Always better to have a spare engine. At least you will only be off the road for a day or two, and that is to swap out the engine.
One other thing I forgot to mention, when replacing rings, don't forget to glaze bust the cylinder bores before you gap the rings.

If when you get the dimensioning done on either the crank or the crank case, be prepared to spend money. A reground crank is not so bad, but a crank case will cost you. Reboring an engine is expensive because you will need to buy new pistons as well.


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Offline muppet

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Re: rebuild
« Reply #5 on: 11 September 2009, 19:50 »
ahhh man!!! lol only reason why im thinking im loosing power is because a few weeks ago i did a silly thing!!!

red lined the engine a few times and then had a pop and smoke out the back!!!!

after i drove a bit smoother and calmer the smoke went away?

could this have caused the power loss because i dont know what that means?

Offline danny_p

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Re: rebuild
« Reply #6 on: 12 September 2009, 00:16 »
you can normaly bounce kr's off the limuter all day.         if you crash into the limuter big style you can get quite a bit of black smoke ( unburnt fuel )
all the VW's have gone bar 1.

Offline muppet

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Re: rebuild
« Reply #7 on: 12 September 2009, 09:06 »
wasnt black though!!! more grey whiteish? after about a mile or so at "decent" driving it went away!!

i didnt want to think the worst but could it be piston rings?

Offline DarnPB

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Re: rebuild
« Reply #8 on: 12 September 2009, 10:05 »
Was it steam or oil smoke? Could be the head gasket, but you will find out when you pull your engine apart. :wink:


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Offline muppet

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Re: rebuild
« Reply #9 on: 12 September 2009, 15:25 »
im pretty sure it was oil smoke but i kno i have been burning oil as told by a friends who to me is a haynes manual!!!!

would a compression test tell me all?