golfRdaddy
Go Kart Newbie
- Location
- Bakersfield
- Car(s)
- 17R / 16R
deja vu 
7
Indium Gray Metallic Money Pit Mk7.5R
- Thread starter scrllock
- Start date
a few bolts later and she's out
Got stuck on that long ass bolt connecting the bevel box the shaft on the DSG but it's real close. Waiting on some tools, expect to have it on the stand and open this weekend.
Injectors and HPFP are at nostrum for bench-testing and rebuilds. I compared the bosch DI that came out to my original continental DI and this is 11k miles on top and 25k on bottom.
The shop that replaced the motor did not use the intermediate ring when installing the bosch DI kit (https://injector-rehab.com/product/vw-audi-gdi-intermediate-ring/) and my theory is that caused the injector to protrude an extra mm or so into the cylinder, causing improper combustion and potentially overheating the injector and one side of the piston rings. I had someone test this on a spare GTI head and it did seem to protrude slightly more.
If that's the root cause, well, my fault for not checking that and having them buy a kit without the pizza toppers. Presumably a more VW-oriented shop would have caught that, but that wasn't really an option. Once I can personally verify everything on my head I'll do a detailed PSA on the bosch retrofit, I'm sure I'm not the only one to screw this up.
In the meantime ordered some more random bits. Oil pump chain and tensioner, balance shaft sprocket, turbo bolts that I nearly stripped, all the one-time-use bevel box hardware. Technically the whole balance shaft, needle bearing, and sprocket are supposed to be replaced, but most people seem to re-use them if they're not scored. Might need a new DSG oil pump motor, the whole thing is one assembly and we broke off the pin cover that interfaces with the harness. Stupid mistake but it's not extremely expensive.
Very nervous and excited to open it up and evaluate damage. Praying there's no damage to the crank, mains and head.
Got stuck on that long ass bolt connecting the bevel box the shaft on the DSG but it's real close. Waiting on some tools, expect to have it on the stand and open this weekend.
Injectors and HPFP are at nostrum for bench-testing and rebuilds. I compared the bosch DI that came out to my original continental DI and this is 11k miles on top and 25k on bottom.
The shop that replaced the motor did not use the intermediate ring when installing the bosch DI kit (https://injector-rehab.com/product/vw-audi-gdi-intermediate-ring/) and my theory is that caused the injector to protrude an extra mm or so into the cylinder, causing improper combustion and potentially overheating the injector and one side of the piston rings. I had someone test this on a spare GTI head and it did seem to protrude slightly more.
If that's the root cause, well, my fault for not checking that and having them buy a kit without the pizza toppers. Presumably a more VW-oriented shop would have caught that, but that wasn't really an option. Once I can personally verify everything on my head I'll do a detailed PSA on the bosch retrofit, I'm sure I'm not the only one to screw this up.
In the meantime ordered some more random bits. Oil pump chain and tensioner, balance shaft sprocket, turbo bolts that I nearly stripped, all the one-time-use bevel box hardware. Technically the whole balance shaft, needle bearing, and sprocket are supposed to be replaced, but most people seem to re-use them if they're not scored. Might need a new DSG oil pump motor, the whole thing is one assembly and we broke off the pin cover that interfaces with the harness. Stupid mistake but it's not extremely expensive.
Very nervous and excited to open it up and evaluate damage. Praying there's no damage to the crank, mains and head.
Hardest part of the tear down: getting the $700 oil pan off while still being re-usable.
Trick ended up being the Lisle gasket separator tool plus some repeated soaking in 3m adhesive remover. Hoping this corner is ok, thinking maybe a paper gasket plus RTV next time.
If it leaks, going straight to a cheap OEM baffle/pan, though.
Got the head and upper pan off and honestly, uh, super underwhelming? Like the boroscope indicated, there is some very minor damage to the cylinder walls, enough material that I can pick up ferrous strands with a magnet.
The head looks great, maybe a couple visual marks on the cam journals, but nothing to the touch. Still need to get the balance shafts out and inspect the rest of the bearings, but besides some burnt-smelling oil, nothing really pops out?
I'll have the machine shop bore it out, make sure the clearances are perfect, and probably have them make sure the head is flat and valve guides aren't worn. If I'm feeling froggy, re-paint the block so it doesn't look like it came from Florida. Feeling pretty relieved today!
Trick ended up being the Lisle gasket separator tool plus some repeated soaking in 3m adhesive remover. Hoping this corner is ok, thinking maybe a paper gasket plus RTV next time.
If it leaks, going straight to a cheap OEM baffle/pan, though.
Got the head and upper pan off and honestly, uh, super underwhelming? Like the boroscope indicated, there is some very minor damage to the cylinder walls, enough material that I can pick up ferrous strands with a magnet.
The head looks great, maybe a couple visual marks on the cam journals, but nothing to the touch. Still need to get the balance shafts out and inspect the rest of the bearings, but besides some burnt-smelling oil, nothing really pops out?
I'll have the machine shop bore it out, make sure the clearances are perfect, and probably have them make sure the head is flat and valve guides aren't worn. If I'm feeling froggy, re-paint the block so it doesn't look like it came from Florida. Feeling pretty relieved today!