Ho ho ho, Merry Monday.
Lots happened over the weekend - including me slicing a large gash in my thumb. ****** 1.8T engines.
Anyway...
Hello K03-011. Awwwww.
Got to work on Saturday morning with the engine.
Rocker cover off immediately led to the discovery of the rattling noise the engine had... Not oil pressure, but a shagged cam chain tensioner. And to be fair, it is completely demolished...
You may notice that in the above picture - there is the chain tensioner. It also happens to be missing the plastic chain guide that lives on the top - shown in the image below (not my image):
So, that was the rattling noise accounted for. What we also found scattered all about the place were the remnants of the plastic guide. Quite a few bits dotted around the head, largely melted. Also few bits stuck in the oil galleries when the head came off.
However most of the plastic appears to have ended up in the usual place.... Good old predictable 20Vs.
New pickup pipe for me then. Oil pump is fine however, and also looks very new, which is a bonus. One less thing to buy.
Back to the engine then... Once the sump was off I could immediately see it is a 20mm block. Bonus. Easy to tell as the rods have securing 14mm nuts as opposed to the bolts that the 19mm rods have.
Block is in REALLY good condition - bit minging, but that's to be expected. Bores have no lip on them at all. Adding to that, they have clearly been recently honed (when the new engine was fitted it would seem). Piston rings also look very new as well which pleases me. Again, one less thing to buy and also explains the honing.
Crank in good condition, acceptable wear on the big end bearings so the crank will just be reused. The deck will need a good clean, as will all the oil galleries due to plastic - other than that, spot on. A bit of work and this will be a perfect block for rebuild.
Few pics below:
The picture above does show the slight but not unexpected disappointment with the head - its small port. It's on ebay already being sold as is, get rid of it and source an AGU/AEB one.
Pistons are dirty, but as said before, rings look good and the ring lands are pretty clean. No obvious impact marks, but that said it's difficult to tell until they've been cleaned up - time will tell and I have been kindly offered a set of perfect 20mm pistons if they are a problem.
So - the engine is now apart completely. The block is empty, the turbo is off.
Just put an offer in on some rods from China, and also have all the other rebuild parts in my ebay basket - so just waiting on a counter offer.
Other things now done - the manifold flanges are now filed and flat, and should fit nicely to a 1.8T head. Needed some work to get the flanges serviceable, but not the end of the world.
So - now waiting for parts, and need to prep everything else ready for engine rebuild.... Yay
