Thank you all, well in a few weeks, I will try do what Welly did, but would take me about 5 times longer I guess, I will give CR a call see if they can do a nice price for a recon, and if their Hybrid isn't too far off, then I would be tempted to go that root as well, but don't have much money in hand, thats why I am planning to it myself. 3 DP is already there if that worked out then all I would need in later dates would be a FMIC another remap.
I was inspired with Wellys work, obviously badger 5 conversion on Speedy Steeve as well, but I am not an expert, so was wondering do I need new head gasket when it all goes back in? also with the timing belt, am I likely to mess it up! or does it have some sort of a guide or do I need markings.
Not going to lie to you bud, the timing belt isn't a hard thing to do really, a little mechanical knowledge required - BUT (and this is a big but) access is such a pain.
The engine mount has to be dropped - the support frame removed from the side of the block, before you can even put the new belt round or fit a new tensioner damper. And that is a biatch of the highest order.
That is he only really testing bit - the rest is just mecano.
Basic process is below - only in brief as it's a long old job! At least you have an idea though.
Disassembly:
Remove charge pipe. Remove cam belt cover (a pain). Time engine up using timing marks on the rocker cover and cam sprocket. Undo all ancillary parts - i.e all parts that are on top of, around and connected to the head. Unbolt turbo from exhaust mani. Unbolt head. Remove head. Remove turbo oil and coolant lines from top and underside of turbo. Undo turbo support bracket (that's fun too). Unbolt downpipe. Remove turbo.
Reassembly:
Fit turbo. Bolt up downpipe with new gasket. Connect to turbo support bracket. Bolt up oil and coolant lines with new gaskets and banjo oil seals (Audi dealer only). Fit new head gasket (correct way up - LOL). Fit new head bolts. Torque to 40nm, 60nm, 90 degrees, 90 degrees (there is normally a sheet in with the head gasket to show you the order). Fit rocker cover. Support engine with a jack/axle stand. Unbolt off side engine mount. Remove engine mount rubber. Remove the three 16mm bolts that bolt the frame to the engine. Remove from the bottom (also fun). Fit new tensioner damper. Loosly fit timing belt where it should be. Refit engine mount frame. Time engine up. Fit belt. Turn by hand to ensure no contact. Reassemble everything else in the order it came off.
Not massively hard, but time consuming, fiddly and thoroughly annoying at times.
Get a Haynes manual or equivalent to help you.
And review this thread:
http://forums.vwvortex.com/zerothread?id=2840728. The engine bay not exactly the same - IE turbo pipework is different, and a few other differences - but the basic principle is the same. That shows you how to time up a 1.8t engine.
Don't be fooled though mate, this is not an easy peasy job. You will get tired, frustrated, cut, bashed, achy and thoroughly ****** off.
But the satisfaction is Gooooooooood!
