need help with a checklist for IP swap and headgasket work

[somedumbjerk]

Pretty much everything i need to do this work on my cars I need to order online, so I'm just looking to idiot proof the checklist for the work I need to do.

I plan on putting a Giles pump on my Jetta, taking the TD pump from the Jetta and putting in on the caddy (recently converted from NA to turbo, just need to swap the pump.) while I’m doing that I’m replacing both headgaskets and timing belts. The truck needs both pretty badly, and I’m going to put the 1.9 gasket on the Jetta which has a hydraulic head, along with some ARP bolts 

So the checklist:
Timing tools set
Timing belt x2
Timing belt pulley x2
ARP 204-4706 studs
1.9 headgasket
1.6 headgasket
Giles Pump
GTD injectors
Injector heat shields

So what am I missing? Every time I do a project that disables my car until completion, I always forget something and I end up having no car for a week, which leaves my girlfriend more than a little PO’d. Thank you for the help on this!

[R.O.R-2.0]

if the pump on the caddy runs good, just swap pump tops. its super easy, and doesnt take more than an hour.

only bad thing, you gotta re-tune the pump when your done..

[somedumbjerk]

if the pump on the caddy runs good, just swap pump tops. its super easy, and doesnt take more than an hour.

only bad thing, you gotta re-tune the pump when your done..

yeah the pump on the jetta is pretty fresh so i figured i'd swap it and build out the old NA pump as a spare. or sell it to help fund these cars or the new motor bike.

[8v-of-fury]

Oil, and coolant for both. Might as well put on new filters while you got the oil out.

Proper tools for the old headbolts? 12mm triple square dealio.

Other than that you seem to have a good idea of what you'll need.

[ORCoaster]

Head removal without intake or exhaust removed?  Then no need for gaskets there otherwise throw them in as well. I don't have a lift or helpers so have to part it off and on. 

[somedumbjerk]

sweet! thanks everyone!

[8v-of-fury]

Definitely leave the intake and exhaust on if you can. Breaking exhaust studs will put you in a nightmare.. and could go from an easy job to hell in a matter of seconds. If you have a helper, the head is not heavy with the manifolds on.. 50lbs tops.

[92EcoDiesel Jetta]

When I did the head gasket on mine, I pulled the head with turbo and manifolds attached with no help. What I did was tie the hood straight up with bungee cords, laid wooden planks on the engine bay so I can stand directly over the head and lift the assembly off w/o straining. I wouldn't have been able to do that crouching over. I am just not strong enough to do that.

[vanbcguy]

You guys gotta carry more kegs around!!



Pretty sure they weigh a fair bit more than a cylinder head / manifolds...

[8v-of-fury]

Your not lifting them awkwardly with your back bent and arms straight out though.. at least I hope not..

Are those 11-1/8" Slim Quarters? 85-90lbs Full?? hope to god you are lifting those with your back.. lol

[vanbcguy]

Yup, that's exactly what they are!!

Maneuvering them in and out of the car is a bit awkward for sure, as is hauling them up the stairs.  Hardest part is squeezing them in to the car at the brewery!!  Sure beats carrying boxes and boxes of glass bottles back and forth though.  Normally I'm just doing 2 at a time so I keep 'em upright behind the passenger seat in the footwell, so yeah a lot of the time I'm having to do the 'extend and lift' thing plus get the bottoms unstuck from the bottom edge of the front seat.  Loading them in at the brewery is tough as I usually don't have room to fully open the car door or anything like that.

[R.O.R-2.0]

try putting a 32" sony CRT tv in the back seat of a mk2.. those buggers are heavy.

ive also hauled a few different 500+ lb loads in the trunk area of mk2s.. wouldnt suggest ever doing that..

[8v-of-fury]

I had 627lbs in the trunk of my 84 Jetta just two weeks ago! Boss let me take a bunch of scrap iron to the yard. He said if I get it out I can keep the moulah. Not bad made $75 :d

[RabbitJockey]

i couldn't believe the amount of *** i could haul

[Luckypabst]

I hauled a 900 lb ironworker in my Caddy. I figured with my weight + my dog's weight and a change of clothes, I was right at the GVW of the car. A full tank of fuel put me over the line... Also had to put the machine all the way against the cab because the rear springs couldn't handle the load directly over the axle.

Chris