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Engine rebuild

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Engine rebuild

Hi all, I have a 1991 golf 1.8 gti. Took my car for MOT, but was smoking like hell. The Mot tester said its burning oil thats whats causing it to smoke like this. Got it home and striped the engine to bits. Now i need to know how i should put the piston rings on the pistons and which way they fit. Also where is the best place to get the rings from? Is there a step by step guide on here that can make things easy for me? Thanks in advance

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A Haynes manual is a good start.

Did you do a compression test before stripping the engine, if so what was the results?

What mileage has the engine covered?

What colour was the smoke from the exhaust?
 

1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 317,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.

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Engine rebuild

11 -12 psi in all cylinders but there was back pressure too

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As has been said, Haynes a good place to start.
In my opinion, if you have the engine stripped, I'd be checking for wear /scoring on the cylinder bores. May well be worth getting it honed or re-bored (if it's required) but that would require over size pistons. I would suggest finding a good engine workshop to take a look, they will be able to source the right parts as well. If you have taken the time to strip the engine down its worth spending the money/time to get it properly checked etc. You'll only do it once.
I had a block re-bored, crank checked and a full balance done (I already had the oversize pistons) for Ł700. That included gasket set, rings, main and big end shells. The ring set came with good instructions for fitting. You'll need some ring pliers and ring compressor to get them back in. I got both off ebay for about Ł10.

My rebuild thread I will try and keep up to date: here

K-Jet fuel pressure test guage How-To

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Engine rebuild

Ok so the engine has neen striped out, npt doing any fancy colours just want it running. Now waiting for head back from the engineers and bits to arrive. So here it is.

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Engine rebuild

Here is pic of piston with oil on top

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Looks like you've got some scoring on the bore of no 4 cylinder - what are the other cylinders like? Even if you put new rings in, if the bores are scored, there is still the potential for oil to get past.
It could just be the valve stem oil seals that are shot.
How many miles has the engine done?

My rebuild thread I will try and keep up to date: here

K-Jet fuel pressure test guage How-To

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Engine rebuild

The engineer has said the stem seals are shot so he is replacing them. Mileage wise its a bit scary as Mot in 2013 shows 167 k. Then in 2014 it shows 97k, now it shows 99k.

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Greenmk1 said

The engineer has said the stem seals are shot so he is replacing them. Mileage wise its a bit scary as Mot in 2013 shows 167 k. Then in 2014 it shows 97k, now it shows 99k.

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maybe 2013 was original clocks, and 2014 replacement that said would only be 175k max with average people using cars as toys only. ..



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not a to technical task to replace
a set of valve stem seals probably
no reason to take the engine apart

Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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Engine rebuild

Oil rings were totally worn out, stems seals also replaced as they were also solid. Just got to get the rocker cover breather welded on as there was a lot of rubbish and grit in it. Any idea wot type of weld i should use on it. Mig or gas?

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just do what you think is best
nobody can tell you how to do
things they can only advise you
sit back think and do it the right
way

Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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why go to the extent of taking
your engine apart and giving it
to a third party if you are clued
up to strip it why not rebuild it

Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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Nicci21paul, i gave it to an engineer to get the head skimmed so i dont have any problems later on, at the same time he offered to put the stem seals in. Anyway everything is all put together and turned it over today it started but was miss firing on cylinder 2 & 4. Any ideas what could be causing this?

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I have checked for spark on all leads and is present on all of them.

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swap the plugs around  from
good cylinders to bad if no change
compression test would be
probably the next step mate

Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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have you got the hv leads on the correct cylinder's
1-3-4-2

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They all start with GOOD Grounds.

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hi so the engineering company skimmed the
bare head or did you send it complete and
they stripped it and then rebuilt ?

Last edit: by nicci21paul


Do not know a lot but willing to help if possible

1989 Sapphire Blue Mk1 Cabriolet KR
1985 Atlas Grey Mk2 GTI 2.0 ABF

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Engine rebuild

Hi all, yes firing order is correct 1 3 4 2, also i have got good compression on all cylinders. We changed spark plugs around but was still the same. So now am thinking could it leads, plugs.

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Engine rebuild

Engineering company built the head up as i sent it full.

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