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Discussion Starter #1
I blew it.

My daughter and her 2001 1.8 Turbo are 2 hours away at school and she had a heating problem, I remotely taught her how to check the coolant and top it off. Same thing happened a week later and I had her try to drive it home which didn't work. Long story short, I now have the head off Thanks to D2Beetle's excellent "Bad Timing Belt - Need Head Rework" write up. The head goes to the machine shop tomorrow to see if it is repairable.

This brings up 2 questions -

Two people have said that these motors don't like heat (Duh!) and I should re-ring the pistons or I could end up with a smoker (and I am NOT doing this again - even if I do manage to get it back together).

And the cylinder walls are rusty due to sitting with water in them for the past month while the car made it's slow journey home and I got around to pulling it apart. Will a quick hone clean them up or.........

TIA
Randy
 

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I think it comes down to a number of factors; which are important on any repair.

1. downtime; how quick of a turn around do you want? (replace or repair things)
2. how much money you are willing to spend; cost effectiveness of rebuilding things, replacing with used, new or rebuilt etc.
3. how long are you going to keep the car?
4. how reliable you want the car to be long term?
5. how many miles are on the car; what other parts are due, for rebuild or replacement?

It would seem to me; a thorough inspection of everything would be smart in the typical repair process. This all takes time and money, etc.

1. check the rings, cylinder walls, pistons for damage
2. might as well pull the oil pan for clogging of the pick up tube with carbon, possibly replace the oil pump, check the timing chain, " " tensioner (noisy, clogged?); check/see wear on the main and rod bearings....
3. check the turbo for wear, play, etc.
4. good time to check all the turbo hoses for leaks, worn, broken and especially the whole egr secondary air injection in front of the engine, water pump, timing belt, all belt path accessories... etc. etc. etc. next?

I mean this could go on and on but all of these would be smart to thoroughly go through all the "stuff" to check; for a reliable and correct, long term solid repair. Substantial wear or problems; would push you into a used motor (as mentioned above) or rebuilt long block territory. Then there are those of us; that actually, enjoy a repair project, regardless of the costs, downtime, etc. and like the challenge of going through everything ourselves! :) As with most things; you don't know what is going on; until you take everything apart inspect and check everything. Things could be fine or maybe not! Let us know; what you think about the car and what your long term goals are.

If you did decide to get down and dirty; here is a cool set of video on putting a 1.8T, back together. Just for fun or if you ever did a full on rebuild; a sense of what it would take to get it back together! :)

google: "1.8t engine assembly HOW TO(part 1)"; there are 5 parts to the series of videos. Cool stuff! :)
 

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Discussion Starter #4
I think it comes down to a number of factors; which are important on any repair.

1. downtime; how quick of a turn around do you want? (replace or repair things)
2. how much money you are willing to spend; cost effectiveness of rebuilding things, replacing with used, new or rebuilt etc.
3. how long are you going to keep the car?
4. how reliable you want the car to be long term?
5. how many miles are on the car; what other parts are due, for rebuild or replacement?

It would seem to me; a thorough inspection of everything would be smart in the typical repair process. This all takes time and money, etc.

1. check the rings, cylinder walls, pistons for damage
2. might as well pull the oil pan for clogging of the pick up tube with carbon, possibly replace the oil pump, check the timing chain, " " tensioner (noisy, clogged?); check/see wear on the main and rod bearings....
3. check the turbo for wear, play, etc.
4. next?

I mean this could go on and on but all of these would be smart to thoroughly go through all the "stuff" to check; for a reliable and correct, long term good repair. Substantial wear or problems; would push you into a used motor (as mentioned above) or rebuilt long block territory. Then there are those of us; that actually, enjoy a repair project, regardless of the costs, downtime, etc. and like the challenge of going through everything ourselves! :) As with most things; you don't know what is going on; until you take everything apart inspect and check everything. Things could be fine or maybe not! Let us know; what you think about the car and what your long term goals are.

If you did get down and dirty; here is a cool set of video on putting a 1.8T, back together. Just for fun or if you ever did a full on rebuild; a sense of what it would take to get it back together! :)

google: "1.8t engine assembly HOW TO(part 1)"; there are 4 parts to the series of videos. Cool stuff! :)
All good points Billymade!

The car only has 60K miles, my daughter and I have put the last 15K on it, our 82 year old neighbor put 6K miles on it in 7 years before that, not sure about the first owner, but it seemed to have been well taken care of.
This is her college car, it needs to be reliable. I'd like to keep it on the road as long as possible. I have 40 year old Datsuns and a 76 Chevy Van that I bought when it was a year old, I tend to hold on to my stuff.......

I have until September to get it back on the road for my daughter and at this point I am unemployed and have way more time than money.

I had a German car mechanic friend of mine stop by and take a look. He's done a couple of these before, he mentioned that it isn't that difficult at this point to drop the oil pan, pull the pistons, get them checked, hone the cylinders and put it back together with new rings and bearings. I will also take a look at the turbo to make sure it didn't sustain any damage.

Thanks for the re-assembly videos, I will check them out.

I'll let you all know when the little beast is back on the road!
 

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Well, it sounds like you are on your way; time rich and money poor! A perfect combo for a rebuild in the garage project! :) Please keep us posted; as the build and repair progresses! I know that I would love to see pics and hear about the repair process, what you did/didn't do etc. I'm sure we would all; benefit from your experience! You never know; we all may end up in the same boat as you and end up having to do a head or a whole rebuild! If you keep a car long enough and with these timing belts; it just might happen! :mad: Taking photos; will help you with putting things back together (for reference) and we would love to see them too! :cool:
 

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Discussion Starter #6
Dropped the head off late last Friday at Cylinder Head Exchange in Sylmar, CA. They did a quick dye test and none of the seats showed any cracks. He threw a straightedge on it and was pretty sure he could clean up the warpage, and he would pressure test it on Monday.
Didn't hear back from them until today, head is all done, ready to go!
He said he could get the head bolts for $50, and gaskets for $130, but I'll check around for prices.
Any recommendations on who has the best parts prices these days? I'll do a search next. I'm gonna need a lot of stuff......
 

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BMAParts is awesome, they have a lot of OE parts as well as 3rd party replacements. They drop ship a lot of things from locations close to you. Many times you will have parts the next day even when you do not pay for quick shipment.

Make sure you use SPECE30 for a discount.

Here are some other options

AutohausAz
ECS Tuning
MJM Autohaus
VW Parts | Volkswagen Parts
Audi Parts - Vw Parts - Audi Parts Vw Parts Kit Company - Blauparts
www.cheapvwparts.com
VW Parts, VW Diesel Parts, VW TDI Parts @ Parts Place Inc.
FixEuro.com - European Transmission Specialists - Home Page
Volkswagen Parts 2Go | Genuine VW Parts 25% Off
Bora Parts Inc.
 

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Discussion Starter #10
Thanks for the tips! I've purchased from Blauparts and BMA before. BMA is about 5 min from my house, but I'll probably still have it all shipped, it will be a large enough order for free shipping from probably more than one supplier.
I currently have 7 shopping carts and a huge headache going getting my orders put together, not all suppliers have all the parts I need........
 

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Thanks for the tips! I've purchased from Blauparts and BMA before. BMA is about 5 min from my house, but I'll probably still have it all shipped, it will be a large enough order for free shipping from probably more than one supplier.
I currently have 7 shopping carts and a huge headache going getting my orders put together, not all suppliers have all the parts I need........
I hate you have to order from multiple suppliers, it makes keeping everything straight a PITA.

FYI, check your alternator pulley. If it has a plastic cap on the front it is actually a one way clutch pulley. The clutches seize often and cause all sorts of belt issues. Consider changing it while you have the engine apart.

Good luck with the project.
 

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Glad to hear the head is ok; looks like you dodged a bullet and its great they didn't find any cracks and that it is rebuild-able! Hopefully, the rest of the parts won't be too much; sounds like its going to be more just the time it takes to replace everything and get it back together. How much did it cost; for the head to be: pressure tested, checked for cracks and resurfaced? Inquiring minds want to know! :-}
 

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Discussion Starter #13
I'll pick up the head today and get the total cost, but the rebuild was quoted at $325 and I think the pressure test was $45.

Rest of the parts (from my preliminary research) will be between $400 and $800. It's TMI time - way too many options out there. Does anyone have a recommendation on rings? It's quite a range - from $97/ piston ($388) OEM from vwpartscenter.net to $43/ piston ($172) at ECS (Goetze rings)to $33 for a complete set from BMA (Grant rings). Unless I'm reading the catalogs wrong and the OEM is for a whole motor.

And timing belt kits - Blau's complete set is $259 and includes a serp belt and some no name G12. ECS's is $264 and includes Vaico G13 coolant. MJM is $224 but doesn't include the stretch bolts, but they sell a set of 4. Are there 4 stretch bolts or 7? The other kits have 7.

And gasket sets, again a whole range of prices.

Jeeze......
 

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I can't help you with the piston rings; brand choices.
On the timing belt kit; a number of years ago, I bought the MJMAUTOHAUS kit and it was all OEM brands with the audi/vw logo ground off, at that time. At that time; they had some slow to ship issues, if you are under a tight time frame... you might step up to a faster shipping type, other then "free"; this may not be a issue now but back then it was (I am in new mexico, they are in texas; not far away at all) It was all excellent quality and the parts are still on my car with no issues. The Blauparts kit; has some extra goodies, like a "tech" sheet and instructions on the install; which maybe beneficial if this is your first time TB swap... they also offer excellent support over the phone for any issues you might run into. I not convinced; other parts places, even attempt to do this type of thorough support and extra paper based instructions, tips, etc. ECS; I have never bought anything from them; their prices, always seem higher and i don't see much benefit from buying from them, on basic replacement parts that everyone else seems to offer at lower prices (they do sell some things that other people don't seem to offer, however).

For stock vw dealer parts; I would also, check out Volkswagen Parts 2Go | Genuine VW Parts 25% Off, I haven't purchased anything from them but they seem to be the most aggressively low priced parts I have seen. As with anything; check around, sometimes one place with be higher/lower then the others for no apparent reason, go figure.

FCP Euro ? Genuine & OEM European Car Parts Online has just increased their parts warranty and "wrong part" guarentees; another possible vendor.

FCP Guarantee | FCP Euro

The above link; is pretty aggressive on their part, seems they are trying to fix the public perception of a drop in service they have had lately. Maybe something to take advantage of?

You might work up a full parts list of everything you need and email or fax these to a number of places; get a quote, once you get them all back... you maybe able negotiate, you never know! ;) I think there might be some benefit from getting everything from one vendor; for simplicity sake but sometimes, one place will be substantially cheaper for certain things. Good luck and keep us in the loop; as things progress! :)
 

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Discussion Starter #15
Got the head back - it's SO pretty that I don't want to take it out of the wrapper......

The head was $325 as quoted, the pressure test was included. So with tax it was $352.25.

He had to cut it 0.017 to clean it up


VW Repair 005.jpg
 

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Touring Dude, appreciate this thread and info, no disrespect to you or your efforts, but I HOPE I never need to refer to this thread for information on my car!!

Below is a great tool someone put together for BMW parts, searches multiple sites at once. Although the VW part number will not work, there may be a few other parts sources on the list to check.

Furiousmethod.com - BMW Parts Price Comparison

Good luck and forge forward.

Since you are working on a 1.8t you likely need a new dipstick tube, might want to replace the PCV system and the small black and white check valves. Check the oil pick up closely, you may want to replace it. Put a new thermostat in the engine and make sure the alternator pulley one way clutch is not seized. Serpentine belt tensioner/pulley may need to be replaced as well.

Good luck!
 

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Discussion Starter #17
Touring Dude, appreciate this thread and info, no disrespect to you or your efforts, but I HOPE I never need to refer to this thread for information on my car!!

Below is a great tool someone put together for BMW parts, searches multiple sites at once. Although the VW part number will not work, there may be a few other parts sources on the list to check.

Furiousmethod.com - BMW Parts Price Comparison

Good luck and forge forward.

Since you are working on a 1.8t you likely need a new dipstick tube, might want to replace the PCV system and the small black and white check valves. Check the oil pick up closely, you may want to replace it. Put a new thermostat in the engine and make sure the alternator pulley one way clutch is not seized. Serpentine belt tensioner/pulley may need to be replaced as well.

Good luck!
No disrespect taken, I too hope you never need this thread, this project is a real PITA! Again, Thanks to D2Beetle's excellent write up for getting me this far.

I replaced the dipstick tube last year when it disintegrated. I'm looking at the PCV parts and the guy at CHE already talked me into replacing the oil pump. The thermostat and housing are included in the Blauparts kit, I have one broken check valve, it's on one of the shopping lists that I'm working on and I have yet to go outside look at the alternator pulley, but will soon.
 

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If your pcv hoses and system are brittle, broken and in need of replacement. You might look into some of the aftermarket silicone hose replacement kits that companies, such as 034 Motorsports has made; I believe they are cheaper then buying original vw parts that you would need and ultimately, will last longer (probably "forever"). It replaces the mass of different connected hoses and becomes a simpler two piece setup; most likely the last time you would ever need to mess with the system, aside from possibly having to replace the pcv at some point.

034 Motorsports PCV hose kit:

Breather Hose Kit, Mk4 1.8T AWW/AWP/AWV, Reinforced Silicone - 034Motorsport | Performance Parts for Audi, Porsche, and Volkswagen
 

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Discussion Starter #19
If your pcv hoses and system are brittle, broken and in need of replacement. You might look into some of the aftermarket silicone hose replacement kits that companies, such as 034 Motorsports has made; I believe they are cheaper then buying original vw parts that you would need and ultimately, will last longer (probably "forever"). It replaces the mass of different connected hoses and becomes a simpler two piece setup; most likely the last time you would ever need to mess with the system, aside from possibly having to replace the pcv at some point.

034 Motorsports PCV hose kit:

Breather Hose Kit, Mk4 1.8T AWW/AWP/AWV, Reinforced Silicone - 034Motorsport | Performance Parts for Audi, Porsche, and Volkswagen
Thanks for that link Billymade, I had found a thread on the silicone replacement hoses (mine was soft and I did manage to rip it during disassembly) but Grandma was borrowing the computer that I had the link up on and she closed all my tabs the other day.

All the shopping carts I had open were giving me a headache so I'm in the middle of putting together a spreadsheet of all the current prices and who has what. I'll post it up if anyone wants to see it when I'm done.
 

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Any idea what caused it to over heat?
 
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