Rebuilding a 1.8T ongoing guide

[Jonny95 SXE]

Hi all, Just an idea. I am taking loads of pics while rebuilding a spare engine I have. Is it worth while?

I got hold of a clean AYP (the original handwriting under the rear engine mount is still on the block allong with all of the white part number stamps and labels)

From here the plan was to strip the engine down completely,
hone the cylinder block
rebuild using new forged rods
use existing 20mm wrist pin mahle pistons (since it is one of few 20mm piston engine codes and have been known to handle 500+bhp)
new rings and piston seals
new big ends and crank bearings/seals
port/polish head
renew valve seals
reseat valves
skim head
reassemble

all while re finishing the exterior of the engine.

simple as.

so on night one project kitchen rebuild commenced

unload engine to kitchen and strip to the point just before oil falls out!

on night two.

was greeted by a house mate earlier wondering "what the f&ck is in the kitchen" so that went down well!

I didn't have the tool to remove the head to hand so I did what I could.

I removed:
oil filter housings
Timing belt and tensioner
rocker cover
Marked all cam retainers
Timing chain tensioner
Cams
Timing Chain
Seals removed from cams

All seals where in working order.

The head seems to have minimal wear with cam lobes perfect and hydraulic lifters perfect also

Is there any way which I could test the lifters?

and for progress,

everything has been re oiled now and stowed away wrapped in cling film.

 

[Jonny95 SXE]

and up to current.

night 3

head off,
valve buckets out,
sump off,
oil pump off,
big ends off,
pistons marked
pistons removed.

 

[Jonny95 SXE]

Pistons are off rods now also will take pics.

Thats all for now.

the big cleaning operation is next and paint (boring)

 

[Jonny95 SXE]

Update for tonight parts are finally cleaning up a bit. Got the sump clean, oil filter housing, rocker cover and other pieces cleaned as well as a first pass on the head and pistons. I think I might have the final color scheme sorted also so looking forward to paint prep. all I need now is a valve spring compressor to strip the last of the engine,

where it all began

and ended

is this kind of wear acceptable?

quickly scrubbed

night 4 down...

 

[Jonny95 SXE]

Wrong section mods??

 

[bertrum]

Subscribed. Will be doing the same to my AYP. Making good progress!

 

[Ravey_Cupra]

Just a quick one, why not replace the OE pistons with replacements whilst they are out for peace of mind.

Also whilst apart I would recomend replacing the hydraulic lifters if youve not planned to do so already.

Good thread and worth keeping an eye on..what colour scheme you decided on?

 

[tom w]

Are the ayp blocks any better than the others as mine has an ayp block ? On a x plate I thought these were the later blocks?

 

[daves ibiza]

wel done jon, im doin same now on ayp engine but my engine is at work and not on kitchen worktop love it lol.

keep up good work mate

 

[Jonny95 SXE]

Thanks Dave!

Looking at getting a good valve spring compressor today, seems tough so far as the inlet follower size is only 24mm and most tools are 25 min.

any advice?

 

[R4cup]

Looking good mate & as i have a AYP belly in mine this thread shall come in handy real soon.

 

[bertrum]

Started stripping mine today, wish it was as clean as yours!

 

[joehirth]

I've done one of these interesting little build thread I like it, who's doing the head work?

Joe

 

[Jonny95 SXE]

doing it myself Joe, well except for the skimming...

 

[Jonny95 SXE]

Sorry for not getting more up on this all,

mad busy with workthese days so it is lacking slightly.

So for night 5. Tools arrived to remove all piston rings and valves. standard piston spreader and a motor bike valve spring compressor with a 21mm adapter for the intake valves. Took me ages to sort it out but finally got one on ebay for 30 quid.

right. so head on its side and lets begin

screw driver came in handy as did a magnetised screwdriver for collets and a agnetic pickup tool (impulse buy in aldi the night before)

intake valves out

placed into cardboard to maintain locations

spring compressor in action

exhaust valves out

nice shiny seats with no pithing or marks

intake tracks loverly and clean

exhaust, not so much

next job now is to "decoke" the head and have it skimmed. and also hone out the block. There is a 3 week lead time on rods at least I can have it all painted and ready by then.

nexy updatewill be monday night i'd say.

 

[Jonny95 SXE]

while removing the valves and pulling the stem seals I put a piece of acetake plastic into the bore for the followers just to make sure if you do slip it will minimise damage.
pics are crap but you can jst see it in the second valve from the left

Just for peace of mind really.

 

[joehirth]

Nicely done, how long are you lapping the valves in for? Using course then fine paste too right? Can't remember if you said either, what valves are going in?

 

[wild willy]

Good work fella, i'm enjoying the read.

 

[Random1989]

quality i want to a spare engine to play with like this

 

[crossedmike]

very interesting