Author Topic: Rebuilding a 1.6 (Read 2341 times)

silentdub · « **on:** March 28, 2008, 12:13:40 am »

My MK1 Project car has a 1.6 Diesel that runs, but has been sitting for 10 years, on top of 200K miles. Since I am rebuilding the car, I am planning on tearing the engine down for a rebuild.

I understand the head is known for cracks? Any info on that?

Also, should I have the block bored? Heads shaved? Anything in that area to do?

Anything that I should consider? I will replace all bearings, seals, gaskets rung, etc.

I guess of the crank isn't torn up, or the rods bent, I can re-use them.

What do some of you guys think?

burn_your_money · « **Reply #1 on:** March 28, 2008, 01:28:01 am »

It really all depends on what you find once you take it apart and start measuring

silentdub · « **Reply #2 on:** March 28, 2008, 10:42:36 am »

Quote from: "burn_your_money"

It really all depends on what you find once you take it apart and start measuring

Is there anything specific that I should be looking for?

burnt_servo · « **Reply #3 on:** March 28, 2008, 03:04:18 pm »

take the injectors out carefully , you can crack the head taking those buggers out .

the heads crack between the intake and exhaust valves .
if you see cracks have it presure tested before spending money on it for machining ,

jtanguay · « **Reply #4 on:** March 28, 2008, 03:41:38 pm »

follow libbybapa's method of 1/2 turn on the injector, then 1/4 turn back, then 1/2 turn out. if it ever gets to the point where its really hard to turn though, turn back then turn back out again. forcing it will likely crack the boss like said above. the reason for the 1/4 turns back in is to loosen the crud in the thread that will build up. when re-installing the injectors put on some anti seize so it will make life easier the next time around, or if you decide to install new/better injectors or run a compression test.

silentdub · « **Reply #5 on:** March 28, 2008, 06:09:39 pm »

Quote from: "burnt_servo"

take the injectors out carefully , you can crack the head taking those buggers out .

the heads crack between the intake and exhaust valves .
if you see cracks have it presure tested before spending money on it for machining ,

Is it a common fix to weld and maching if there is a crack? I know a few other vehicles, that is an option but I am not sure on the 1.6.

Thanks again!

burnt_servo · « **Reply #6 on:** March 28, 2008, 06:41:04 pm »

aluminum is easily welded and machined ........

BUT if you search around here , there are some links to guys selling new 1.6 and 1.9 heads for under 300.00 ...... so it's not cost efective to even try to fix a old head

Clankin-Rabbit · « **Reply #7 on:** March 28, 2008, 08:29:49 pm »

Quote from: "burnt_servo"

aluminum is easily welded

IF you're a skilled welder w/ experience....