Delicate starting procedure

[rubjonny]

yep fraid so. before you start check which inlet you have. if its the larger 50mm one then if you can, unbolt the inlet at the bottom as then you wont need to replace the upper gasket. this is a problem as the 50mm upper gasket is NLA at VW and I dont think any pattern parts are available

the lower gasket is available from GSF, and they also do the smaller inlet upper gasket:

11047 - VALVE COVER GASKET SET - 9.85
11816 - INLET MANIF.GASKET-UPPER - 4.10
11817 - INLET MANIF.GASKET-LOWER - 2.20

[Harooshum]

Hello - thanks for all your info, looking at the 2 sparks i did manage to take off, they are not right.  They dont have the fingers at the top, and looking with a torch into the holes, I can see the 3-prong fingers stuch in there.  So that means I have 4 plugs that cant be taken out.  I thought about sticking a long screwdriver in between those fingers amd twisting it out but I dont want to as they will probably snap off into the cylinder.

So it looks like the head has to come off - good opportunityy to get that lightened and balanced 2.0 9a bottom end mated with a new polished and ported KR head that I always wanted - cant find any!  I think my most likely route will be to keep the 1.8 KR bottom-end in the car, and buy a refurbed but not modified KR head and use as a daily driver.

There is no shortage of 2nd-hand KR heads on the market, but they are all old and i might as well get one that has been refurbed with new cam chain and valve seals etc (polished and ported not absolutely necessary for daily driver - but would be nice  ).

Anyone know of any companies who sell complete refurbed KR heads?  thanks!

[bodga]

M 16valver had deen standing aout 10 years according to the last owner. Ihad to replace both fuel pumps before she fired up and then i had to give the air meter a good clean up.The needle was stuck so i wrapped it in a rag and pulled it out with some pliers. cleaned it with petrol and she runs sweet now. change the cam belt asap. mine was ready to snap! I enjoyed getting it running thou. both pumps i found off ebay second hand. good luck

Not sure what you mean.  I used to take apart the entire air filter housing along with all the parts to and including the throttle, and give it a good clean with carburettor cleaner along with the isv valve as part of my regular servicing if thats what u mean - stuck needle???

sorry im a bit late replying and sorry to hear about the plugs breaking up.
The needle i was talking about is the one the air meter controls. it sits inside the fuel distributer, when i pulled the air plate (disk) up it was very tight and every time i got the engine runing, it would flood itself, until i pulled the needle out and cleaned it.

[Ben Lessani]

... I think my most likely route will be to keep the 1.8 KR bottom-end in the car ...

How come you don't want to change to 2.0 - it will give you a lot more bang for your buck than a beefed up,expensive  KR head?

Anyone know of any companies who sell complete refurbed KR heads?  thanks!

Perhaps TSR?

http://www.tsr-performance.com/pages/heads16v.asp

... read this http://www.golfgtiforum.co.uk/index.php?topic=133092.0;topicseen

[Harooshum]

Ive done it! Bought a standard abf, will collect it tomorrow. I can't find anyone to do the work so taking 2 weeks off work to do this myself. Iv done all sorts of servicing and replacing parts but never an engine transplant!  THEN I started looking into it more on this site and now I'm worried about the kjet fuel system, isn't it supposed to be a straight engine swap?

Anyway I'm looking to sell my kr on auction site so the new owner can remove the head and sort the plugs themselves. But they will have a good motor!  Maybe I should have waited for a decent 9a instead!!