1G rebuild

[turbotalon46818]

Im about to start rebuilding my 92 tsi awd. Complete tear down and rebuild. I have been a mechanic for a few years so i know the basics. Is there any tools or tips i should know about before jumping into this? any Dos and Donts? any help would be appreciated
Thanks guys

 

[turbodsm_125]

find the timing belt tool! it makes life alot easier! also do a balance shaft removal on the engine while you have it out. it give 10-15hp and makes timing the motor way easier. if you have any questions feel free to pm me. i just finished rebuilding my 1g motor for the first itme. quite the learning experience...

 

[pj91gsx]

If your like me, you can learn to do timing with out the timing belt tool. Its really not that hard to do it without the tool you just have to set the exhaust cam back one tooth.

most importantly: keep the rod caps with there original rods, piston's arrow point to the timing belt, main caps point to the tbelt. main caps are marked for there places of course. read about how the piston rings need to be set. the compression ring's end gaps are 180 degrees from each other. Read the box for install directions on them. make sure you dont flip the timing plate backwards, All of the caps on the head are marked with I meaning intake and E meaning exhaust and with number like I1 I2 I3, E2 E4. etc. make sure the head block and gasket are very clean be for your put the head on, I used asatone. Spray, copper coat on the headgasket. It will stick like crazy. good luck!

 

[6bolt_tsi]

Another thing to note, if you remove the balance shafts then you don't need to make sure the oil pump is aligned with the crank etc etc. Since your doing a complete tear down, now would be a good time to replace both the idler and tensioner pullies, auto tensioner,water pump, oil pump gears. What the hell, go ahead and change out the lower timing cover too Another thing to inspect is your oil pick up....make sure the screen is clean of debris, if not then change it out. Its only like $30-$40 at the dealer in my area.

If you reuse any old parts, please take the time and clean everything. I like to use "Brake parts cleaner"

 

[pj91gsx]

IMO spend your money where it matters. if you timing belt cover is fine leave it, I would not spend an extra 75 dollars to get a new one.