[mandjpierce]

Timing belt stripped out around crankshaft pulley on highway. Pulled the head and it looks like several bent valves. In addition...The piston heads look pretty banged up.....Any suggestions on how to tackle this?

Thank YOU!

 

[billymade]

You might read; this 1.8T head DIY:

http://newbeetle.org/forums/1-8-liter-turbo/35490-bad-timing-belt-need-head-rework.html

This page post #48; recommendation, is sand down the top of the pistons, where valves made contact:

http://newbeetle.org/forums/1-8-liter-turbo/35490-bad-timing-belt-need-head-rework-3.html

The head damage:

Needless to say; you need to ship the head out for repair or do a exchange with a cylinder head shop, if you want to speed things up, these guys have rebuilt heads for a reasonable price: do a google search for other vendors, $650 to $800 seems to be the going price for a rebuilt head for a 1.8T:

http://www.shop.headsonly.com/VOLKSWAGEN_c28.htm

http://www.cylinder-heads.com/automotive-cylinder-heads/

We have dealt with them at my brothers shop; had good service from them.

If your low on cash; you might try a junkyard or look on a used head on, ebay or in the classifieds on vwvortex.

 

[mandjpierce]

Thanks for the links....i got some reading to do!

 

[mandjpierce]

Ok.....So I refinished the pistons with the dremel....I think they turned out ok...super smooth...im a lil worried about the forward edges....but I guess we will try and see! while rotating the pistons I noticed something....when the number one piston is at the very top of the cylinder,,, the timing mark on the crankshaft sprocket is at the 4 o clock position....I know I don't have the back cover on for reference,,,but the timing mark on the cover is at approx. 12 o clock.....the first two pics are the #1 piston at the very top...and then a pic of the crankshaft sprocket when it is in this position.....the other pics are just of the finished resurfacing......am I mis understanding the concept of T.D.C.? or whats going on here? im very confused....

 

[VDubYah]

Sorry to hear about your belt.
The crank timing marks are on the lower cover and the harmonic pulley. You will need to temporally reinstall them to see TDC at the crank. You will need to back off TDC just a little to install the head and not have to worry about the knocking the valve on the piston top while installing the head.

 

[mandjpierce]

Ahhhh....that makes more sense.i wonder why they put a mark on the sprocket? Makes it confusing..i dropped the head off at machine shop yesterday..and now.....i wait

 

[D2Beetle]

Nice work! :goodjob: You can find TDC by using the fly wheel; there is a small view port at the top of the Transmission.

 

[billymade]

Any updates? How did this repair turn out? Inquiring minds; want to know!