RichLV's UrS4

[BATCH]

nice job!! I love you car!!!

[RichLV]

Can you expect the cost of rebuild?
I wish i could rebuild mine soon.

If I factor only the engine costs, then around 2.5k. If start to count my every idea that came to me while I was at it, then a lot more.

The problem was that I did not know in the start what exactly will need to be replaced when the block came out. With each step I took it turned out I need to get something extra again. This car has not seen good care for a long time and that's why I'm paying for it.

[popdemonic]

Can you expect the cost of rebuild?
I wish i could rebuild mine soon.

[RichLV]

Silicone water hose kit for my UrS4.

[RichLV]

Aaand parts again.



Head will be done in about a month.

[RichLV]

Parts, parts, parts everywhere!

[UrS4boy]

Billet crank pulley from Terrybullwon. Actually panicked in the beginning a bit, since the left top hole is offset from the others, but then looked on the OEM and it is the same.

It's like the flywheel in the sense that things can only go back together the same way, in this case the damper pulley only bolts on one way (there is also a dipple on the OE sprockets that helps with this)

[RichLV]

Billet crank pulley from Terrybullwon.



Actually panicked in the beginning a bit, since the left top hole is offset from the others, but then looked on the OEM and it is the same.

[RichLV]

The frankenstein block is out. Clutch and flywheel removed and ready to be fit to the new block. Turns out I need a new/another right engine mount, this one has been cut and welded aaand both of the engine hydromounts are toast, both screwrods are torn from the mounts.




#@$%^#%&#!!!

[RichLV]

Finally the bottom end has been assembled. Everything went smooth. Rods and pistons were assembled, new rings installed. All bearings did fit properly and the crank is turning easy. Everything was lubed with Motul 8100 X-Cess 5w40 oil while assembling. Everything torqued to specifications. Big thanks to my dad for assisting me in this task.
Some pics:

















Next - cylinder head!

[RichLV]

I'm currently looking for RS2 or RS2-style (Wagner evo probably) exhaust manifold. If someone has offers, please contact me. Also created a thread in the Wanted section.

[RichLV]

Updates!!

Final parts have been received and initial bottom end assembly is now possible. Most likely will assemble next week. Last parts were OEM main cap bolts & piston pin retaining rings. I opted for Mahle piston rings. Had to buy additional sump gasket, cuz the VR set only contains one.



Still need the bottom crank pulley & damper, oil return valve, thermostat, waterpump, timing belt kit, timing belt covers, and some other small stuff. But mostly it is finally going forward. After the bottom end, I'll start searching for RS2 exhaust manifold and rebuilding the head.

Soon...

[RichLV]

The rods are here! Thank you FCP-Engineering!









A little insurance not to bend anything when I'll try to map VEMS for the car.

[RichLV]

The block and crank are back from the shop and everything is great.

Crank is near perfect, all within standard dimensions, no grinding was necessary it was just polished and is ready to go in.



Block has seen a bit more and there's little signs of wear right at the top ring, but still, all measurements were in factory spec and no bore was necessary. All 5 cylinders were honed and the surface was cleaned.





Next stop - rods & bearings.

[RichLV]

I agree.

Got the valves out and did another check for cracks. We're all good, no cracks found during second check.



So the exhaust valve guides are toast. The valves are rocking very very badly. Those will need to be replaced. Intake is fine, some are debatable, will measure with new valves. Exhaust valves are going to be improved a little, the valve is pretty heavy and the tulip form will be improved a little. No porting will be done, just cleaning, cutting the angled valve seats and new parts for the head. Valve stem seals are OEM VW, so it seems the head has not been touched since '92.