Head removal

[Graham]

Cheers for all the advise, my bits should have arriverd yesterday but havnt, will be here soon fingers crossed. The job sounds a bit of a nightmare but i am sure i will manage. Hopefully today i will either have spun the engine and through some miracle there has been no mass collision of metal, or i will have the head off and apart. Once again thanks
Graham

[Graham]

Right after a fun packed holiday off work i have got the head off in 5 hours, all the turbo studs/down pipe bolts/wastegate bolts were heavily corroded, to the point where they were too small for a 12mm key but too big for a 11mm key, and even then 3 sheared . The damage is quite mad, cant quite suss it out how its happened . Good news is all exhaust valves are/or seem to be ok (havnt got the valves out yet but spun the cam and they work, also there is no marks of a collision on them. Will fela gauge them tomorrow (depending when i wake up). But the bad news is ALL the inlet valves are bent . Pistons have some light marking, but nothing that wont rub down and i am well chuffed at how good a condition the cylinder bores are. Now am i right in saying the inlet valves are the cheap ones (ohh please ). Other things i spotted on the way was a close too splitting hose that just sits under the throttle body into the manifold, and i might have a minor problem with my PCV system. I noticed a small amount of oil on the hoses and gubbins down the back of the head near the bulkhead. the oil looked like it has been sprayed out, well more like the gunk you get out of a breather. I will look into this. What should i look for, where are the main problems assosiated. Took a few photos but my brother has my card reader so will have to wait to get them on the site. Sussed out a nicer user friendly way of getting off that sh*t design turbo to manifold and turbo to down pipr connection. I removed all the nuts leaving every thing hanging on the studs, then went under the car and removed the CAT to gearbox bracket, then lifted the head up complete with exhaust system and got a friend to tie back the exhaust and turbo while i removed the head and manifold as i didnt like the look of the pipes onto the bottom of the turbo (oil and water).
Well thats all for now
Graham

[91_S2]

Graham,

Sorry to hear about the valves. You never wrote the reason you are lifting the top. Did your timing belt slip? Good luck

[Vagsport]

Sorry to hear about your mishap, Graham. Did your cam belt slip / break? At least, the inlet valves ARE the cheaper ones, the exhaust ones are too far from the pistons to ever make contact, even if the pistons are right at the top of their travel and the exhaust valves are fully open.

[Graham]

I like the idea of using brass as the guide material, brass is a lot more ductile than cast iron and have a lot more give before they crack, the valves guides seem in good condition, there is hardly any radial movement on the stems I just hope the inlet guides are ok.
Graham

[Graham]

There is alot of talk about ensuring the cam bearing caps are put on correctly, and i there original position. I cannot see how anyone could go wrong as mine are all numbered (1- 10 i think) and are marked across from the head to ensure alignment.
Graham

[Graham]

Help, i need a new exhaust manifold, one leg has a crack 3/4 of the way round, and there is about 5 other cracks. Also i need a hall sensor and the magnet for the cam pulley. Please if anyone has an S2 manifold to get me away i will be very greatfull.
Graham

[APNess]

Off to work right now but will check the S2 manifold I have that came off when I get home tommorrow. My old hall sensor was completely fooked, so can't help you out there, sorry

I'm in Leeds, so not that far away either (heh, I pass through Middlesbrough on the train just about every night on the way to Redcar - apart from this week. Not sure the signalman in Middlesbrough 'box would appreciate a 17 wagon train blocking the station up whilst I drop off an exhaust manifold, and speed is 25mph through there, so might be a bit dangerous to throw!)

Will advise ASAP (tommorrow)

PJ

Picture - no idea if it's any good or not, but as far as I know should be fine. My problems started when the new bits were put on :S If there's anything specific you want a photo taken of, or want a detailed photo (12 megapixel takes about 4.5meg though, so will have to email it) of any part of the manifold, let me know.

[audiman]

I too have a stock manifold that has no cracks and i have had the face skimmed flat as they tend to warp. PM me if you want it

[APNess]

Probably better off with Toms then. I think I'd struggle to get anywhere near a post office this week to send it off, judging from the night shift I just did. Bedtime zzzzzzzz

[Graham]

Hi all, i have fully stripped the head (except guides) and the head is getting crack tested and will be back on friday evening ( please be ok), there was a less than 0.05mm gap under the straight edge (smallest feeler i have) so it is well within tolerance . I am getting the guides checked out but to me they seem fine with virtually no play in them at all. The collets and caps are being crack tested and i am awaiting bits. Few days off next week to re build as the bits are looking at coming on Tuesday and GTi is very close .
Graham

[Graham]

Hi i am waiting for bits, i havnt got my head back yet from crack testing, here is a few pics of the damage:

[Graham]

And here is my baby in a poor state:

[Graham]

Are green injectors Green to look at because my injectors are green in colour. :

[Beetie]

God youve got your work cut out this week m8! Hope you get it sorted quickly!