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Thread: Tony's (GTI-07) Engine Rebuild Blog

  1. #1
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    Talking Tony's (GTI-07) Engine Rebuild Blog

    Day 1

    *pictures taken with iphone*

    Tonight at 7.30pm we started the engine rebuild process.

    To assist in the removal of the engine from the car, the whole front section was taken off (bumper, headlights, radiator/intercooler etc.)

    Misc. parts from front of car and engine bay




    By removing the front section, it allowed for easy access to disconnect all the wiring and plumbing to the engine. Exhaust and driveshaft was also unbolted at this stage.

    The engine was removed with a engine hoist and supported underneath for extra precaution with a trolley jack.

    Empty Engine Bay


    Engine out of car


    AWE KO4 Turbo


    With the engine out, the next step was to remove the DSG gearbox from the engine block.

    Tony hard at work hehe




    DSG GB


    The engine will be getting Arias pistons and Pauter rods. The head gaskets and bolts will be replaced with new items.







    End of Day 1

    Day 2 will consist of removing the rest of the bits and pieces off the engine block so that the head can be removed and the internals are cleaned up and prepped for the installation of the new parts. The aim is to have the engine opened by the time the BBQ starts so that people will have a chance to see the insides of the GTI motor and its components.

    Thread will be updated as more progress is made.
    84 MK1 GTI
    01 DC2R

  2. #2
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    Whack some Head studs in while your at it... if you have bigger rods and pistons you will want big boost to make the most of it and that will lift the heads on stock bolts (at least it does on jap cars). I had 15mm head studs in my subaru's stroker block.
    *Disclaimer - Don't rely on me, seek your own professional advice. Audi R8 E-tron. 230kw 4500nm! (not a typo).
    Economy at 100kph =5.5L

  3. #3
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    you guys have too much bloody money

    I might pop in tonight and say hi
    VW: it aint just a car, its a way of life
    There are few things more satisfying in life than finding a solution to a problem and implementing it
    My Blog: tinkererstales.blogspot.com.au

  4. #4
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    hahah they do, not me!! my car still stockish LOL
    84 MK1 GTI
    01 DC2R

  5. #5
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    Quote Originally Posted by Big Yellow View Post
    hahah they do, not me!! my car still stockish LOL
    its about time you manned up and got a turbo kit for you R32 innit?
    VW: it aint just a car, its a way of life
    There are few things more satisfying in life than finding a solution to a problem and implementing it
    My Blog: tinkererstales.blogspot.com.au

  6. #6
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    Quote Originally Posted by GoLfMan View Post
    its about time you manned up and got a turbo kit for you R32 innit?
    thats what lucas keeps saying!

    minor update: Tony and Lucas didnt finish working on the motor till 5.30am this morning lol. head has been taken off and block has been gutted. Head was not looking flash hot so has been taken in to get prettied up.
    84 MK1 GTI
    01 DC2R

  7. #7
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    Quote Originally Posted by Big Yellow View Post
    thats what lucas keeps saying!

    minor update: Tony and Lucas didnt finish working on the motor till 5.30am this morning lol. head has been taken off and block has been gutted. Head was not looking flash hot so has been taken in to get prettied up.
    jesus, thats keen!

    what was wrong with the head?
    VW: it aint just a car, its a way of life
    There are few things more satisfying in life than finding a solution to a problem and implementing it
    My Blog: tinkererstales.blogspot.com.au

  8. #8
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    Quote Originally Posted by GoLfMan View Post
    jesus, thats keen!

    what was wrong with the head?
    not sure exactly! will try find out later today!! i think tony is still sleeping at the workshop LOL
    84 MK1 GTI
    01 DC2R

  9. #9
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    Quote Originally Posted by Big Yellow View Post
    not sure exactly! will try find out later today!! i think tony is still sleeping at the workshop LOL
    orite you twisted my arm, cya at 630pm big fella
    VW: it aint just a car, its a way of life
    There are few things more satisfying in life than finding a solution to a problem and implementing it
    My Blog: tinkererstales.blogspot.com.au

  10. #10
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    Rebuild components from Lucas:

    Its getting Lower Comp, forged Pistons
    Stronger Rods
    New Custom Piston rings.
    New BigEnd Bearings
    Engine will receive a light hone through bores, bores are not damaged in any way.
    Head is getting a Major clean from all the Carbon and Gum build up due to FSI engine setup, this Build up is bad and happens to all direct injection engines.

    The lower Compression will allow tony later with a bigger turbo run a higher amount of boost, without makeing cylinder pressure go out of control, like what happens when you put a big turbo on a stock high comp motor.

    Target is get car done by end of saturday.
    The only thing that is going to hold up if head can get cleaned by end of today.

    Tony has some future plans, so take the opportunity to make bottom end stronger, and replace the crappy stock rings.
    So then he can be ready for bigger and better things later on when he is ready to spend more $ on the car.
    84 MK1 GTI
    01 DC2R

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