Engine rebuild

[WabTheKing]

duno if this is exchange but though it might be useful http://www.eurospecsport.com/db/details.php?id=432

[porkkis]

Buy one set of new piston rings and measure 1st and 2nd ring gap at the depth of about 15mm down from deck level. The gap should be around 0.35mm
Over 0.5mm is what I consider a need for new bores and pistons. Take care the ring is straight, otherwise you get false results.
I've used both AE Hepolite and Goetze rings. Original ones are said to be the best, but they cost silly money. Golf2 1.8 gti 16v KR/PL engines have the same rings so they're easy to find.

If the gap is ok, just get the block honed and use your old pistons. Measure every ring on assembly.

A lot smaller than 0.35mm would mean you should file the ring ends so there is enough play. The minimum should be checked somewhere as I can't recall what it is.

Usually on higher power engines the gap can be a bit more so smaller gap is not always the best. This is because the 1st ring gets very hot and therefore thermal distension will be higher. On higher power engines the temps are also higher.

Get a valve job done on the head. You probably need at least new exhaust side valve guides. On 200k mile engine probably also the intake side.

HTH

[aelred]

Porkkis, surely the use for measuring bore wear with piston rings is not quite correct. It might be indicative but not exact.
I would use proper dial bore gauge. Any good machine shop will check the bores for you with the right tool free of charge.

[porkkis]

Correct. That method does not tell if the bores are worn to ellipse shape etc but I've been keeping that method adequate enough.

[mcandmar]

With 200k miles i would be amazed if the bores were not visibily worn. The ABY i'm rebuilding at 140k miles had very bad wear at the top of each cyl from the rings.

Any good machine shop will be able to rebore/hone the block for you Ski, thats when the expensive project started for me, oversize pistons are pricey so i thought best to go the custom route, then while your at it a set of rods, bearings, oil pump, gaskets, then you have to get it all balanced. Keeping yourself under control is the hard part, i'm way over budget on my build and i havent even looked at the head yet, or fitting the engine. I have the guts of a bottom end and thats it so far

[Audi Parts Guru]

The most accurate method of measuring bore size is to use a dial bore gauge with a torque plate bolted to the block

[aelred]

There are not many people with a torque plate, likely I have one made. To be honest I buy genuine pistons not in the Audi box and I do not find them expensive, so for the rings and personaly I think you cannot beat the original pistons and never suffered any problems with big BHP well above 600. OK they might be a little heavier than competition pistons.

[Ski]

duno if this is exchange but though it might be useful http://www.eurospecsport.com/db/details.php?id=432

that sure does look intersting wab.. seems all the work is done. What else would this block need doing to it?


Im finding it hard to get my head around all of this.. specially now re-boreing and oversized pistons have been added to the list. Shame there isnt a garage that would take on all this work (supply parts, fit, bore, balance etc..)

[Ski]

this is a very good thread to follow.Im planning such a move when i reach the big 200K and although RS2,i do want a good rebuild then.
let the masters begin to write!

Just as an update... here is what im looking at :

Rods sps - £500
Crank shaft - re machined and balanced £?
pistons - depending on re-bore (Mahle) 81 mm is standard, 81.25, 81.5. £600
New Bearings specially if crankshaft is machined
7a exhaust cam or aby - get new
tappets - can be cleaned
valves - measured and recut (no need to replace all valves).

This is just a quick list, and, not everything will need to be done and will be more things that need to be done.. STILL IN PROGRESS

The bottom line is, I cant get an exact figure as I wanted. The engine needs to be stripped and checked as to what is needed to be done. could take anything from 25 to 45 hours labour

[Jamo]

that sure does look intersting wab.. seems all the work is done. What else would this block need doing to it?


Im finding it hard to get my head around all of this.. specially now re-boreing and oversized pistons have been added to the list. Shame there isnt a garage that would take on all this work (supply parts, fit, bore, balance etc..)

MRC and Audiman could do the work but you'd need the cash upfront.

I know another member is looking to do this.

[Ski]

Cash upfront for parts is fine. I doubt they would need cash upfront for labour tho ?

Either way, im still trying to figure out a price, trying to get a price on pistons, 7a cam, bearings, etc.. etc..

its very hard to get a rough price.

[Jamo]

Cash upfront for parts is fine. I doubt they would need cash upfront for labour tho ?

Either way, im still trying to figure out a price, trying to get a price on pistons, 7a cam, bearings, etc.. etc..

its very hard to get a rough price.

Speak to Audiman see how much it would cost.

[AJ ES]

If your engine unit has been totally stripped to a bare block, then get all the core components along to any reputable engine reconditioner ( find them at www.fer.co.uk)and they will tell you what work is required from Rebores to Regrinds. All OE parts like Pistons, Valves, Bearings ect are not manufactured by VAG. In fact VAG probably never made any pistons or valves or bearings in any great quantities. A close examination of these parts should tell you who manufactured these parts, from mahale to KS and TRW to AE also glycol and ACL.

[Ski]

Me? strip engine to the bare block? then take it places? on my bike? I dont even have a drive way

Thanx guys for all ur feedback. What I think I will do is.. Get an idea of what I want, give it to someone respectable and ask for a bill

Will keep you lot posted

[Stick Insect]

Shame there isnt a garage that would take on all this work (supply parts, fit, bore, balance etc..)

Ski, there are many places which will do thae work. One company Which I can highly reccomend is
Engine Rebuilder / Engine Reconditioning Company: Quasar Engineering
Telephone: 0161-430 7643
Address: UNIT 3 Welkin Rd, Bredbury, Stockport, SK6 2BH

They build Formula Ford engines which has to be one of the most competitive engine building sectors going.

They will do all the work apart from fitting and removing the engine. Dave Bower may be able to do that for you 01625-820223 just between Woodford and Poynton.

David