Rebuild of 1.6 TD engine

[Diesel Fumes]

Sorry for asking.  I am searching throughout the forums for everything I need to know but was hoping for some feedback in this thread.

First off, im not new to VW diesels.  I had a 1.6 n/a for the longest time and before that it was a series of VW gassers.  Those are great cars but after my first diesel I was sold.  MKII diesels are my favorite car for a daily driver.  Now I have a TD which runs really well, but the engine is greasy, oil on the turbo seals, has been running uprated boost for a few months now, has 250,000km on it.  I want to completely rebuild the engine.  Is there a parts list of what I need or is there a complete rebuild kit available?  I really just want a good tight engine with good compression that doesn't leak oil and gets good fuel economy.  Perhaps a partial rebuild is OK.  

I am also looking to upgrade the turbo and injectors if this would be of benefit.  What size turbo is ideal?  Do I need to have intercooler if I upgrade the turbo size?  Also, if the stock pistons look good, can I stick with them or is there a suitable upgrade available?  I would like for my car to have 120-ish horsepower when I am done with it.  






I have already ditched those fog lights in case someone was going to mention them.

[smutts]

If the cabin heater isn't leaking yet, you might want to look into the retrofit VW did to stop the crappy french made heater matrix from bursting. Did VW ever sort this out during the production run or is it a necessary fix to every single A2 made? :?:

This may not be relevant to you lot over the pond.

[Baselyne]

ive read something about this in Golf+ magazine's ask the brain

i was wondering also if there all like this or is it just in euro models?
I suppose I couldnt see it being very different although who knows maybe the few more inspections of making it to the US would have busted the recal or was there ever a recal?

[Black Smokin' Diesel]

Even MK2s in north america had problems with heater cores leaking. It even happened in my dad's 91 passat (B3).

I would replace the valve cover gasket as it seems to be leaking pretty bad. The G60 rubber gasket and studs are a good upgrade to the three piece cork crap.

Don't know which turbo you have (t3 or K24) but with a custom downpipe and exhaust, you probably won't need to upgrade the turbo to get 120hp. An intercooler is a good idea, no need for a huge thing though, 2" piping is enough. To my knowledge, there is no upgrade to the pistons (except oversized ones).

Where are you located?

www.germanautoparts.com for the USA and importcarpartscanada.ca for Canada should have everything you need.

[Diesel Fumes]

I read up on the heater core problem.  It is not leaking right now.  Sometimes I get a faint smell of coolant inside the car, but I haven't been too worried about it.  Apparently there was a recall on these model years of car and if I take it to VW they will replace it for free

[Diesel Fumes]

Even MK2s in north america had problems with heater cores leaking. It even happened in my dad's 91 passat (B3).

I would replace the valve cover gasket as it seems to be leaking pretty bad. The G60 rubber gasket and studs are a good upgrade to the three piece cork crap.

Don't know which turbo you have (t3 or K24) but with a custom downpipe and exhaust, you probably won't need to upgrade the turbo to get 120hp. An intercooler is a good idea, no need for a huge thing though, 2" piping is enough. To my knowledge, there is no upgrade to the pistons (except oversized ones).

Where are you located?

www.germanautoparts.com for the USA and importcarpartscanada.ca for Canada should have everything you need.

Im in Alberta and also on vortex.  I think I sold you a gauge cluster for a Late MKII N/A diesel  :lol:

I looked into the turbos.  Im going to see which one I have by looking today.  Its making a whining noise, so I assume it needs a rebuild.

And I can get G60 valve cover gasket on importcarpartscanada?  I love that site.  G60 was 1.8L engine in Corrado?

[cyrus #1]

Apparently there was a recall on these model years of car and if I take it to VW they will replace it for free

I doubt VW will be very receptive about doing free work on a 17+ year old car.  It's worth a shot though.  You can do some more research on the vortex but apparently not all models were covered, even though they used the problem heater cores. :roll:  It's also my understanding that they never actually corrected the problem but just replaced them with the same unit.

[Diesel Fumes]

Apparently there was a recall on these model years of car and if I take it to VW they will replace it for free

I doubt VW will be very receptive about doing free work on a 17+ year old car.  It's worth a shot though.  You can do some more research on the vortex but apparently not all models were covered, even though they used the problem heater cores. :roll:  It's also my understanding that they never actually corrected the problem but just replaced them with the same unit.

A brand new Febi heater core is only $58.  I think I would rather just buy that then have to deal with VW.

[Black Smokin' Diesel]

Im in Alberta and also on vortex.  I think I sold you a gauge cluster for a Late MKII N/A diesel  :lol:

I looked into the turbos.  Im going to see which one I have by looking today.  Its making a whining noise, so I assume it needs a rebuild.

And I can get G60 valve cover gasket on importcarpartscanada?  I love that site.  G60 was 1.8L engine in Corrado?

I did buy a diesel gauge cluster but I don't remember who it was from. IIRC it was mobile363 or something like that

Yep, 1.8l engine. You'll need the studs too.

[jtanguay]

isn't there a time limit on recalls?  or maybe thats the pitch they'll give you in hopes that you 'go away'  :lol:

[Diesel Fumes]

Im in Alberta and also on vortex.  I think I sold you a gauge cluster for a Late MKII N/A diesel  :lol:

I looked into the turbos.  Im going to see which one I have by looking today.  Its making a whining noise, so I assume it needs a rebuild.

And I can get G60 valve cover gasket on importcarpartscanada?  I love that site.  G60 was 1.8L engine in Corrado?

I did buy a diesel gauge cluster but I don't remember who it was from. IIRC it was mobile363 or something like that

Yep, 1.8l engine. You'll need the studs too.

yea, thats me on vortex.

Studs for the valve cover?  I can't seem to find these on the website.  Do I need to source these elsewhere or perhaps they are called something different?

[carrizog60]

what grill setup is that?

[Diesel Fumes]

what grill setup is that?

Just an aero grill with dual rounds from a MKI Rocco.  I think.

[TDDrew]

I'm 99% sure if your vehicle has a recall then the dealer has to do it no matter what.
You could even ask them over the phone if you vehicle has any open recalls.

Looks like you could use a new oil cap gasket as well.

So, what vehicle or engine do I look up to get the rubber valve cover gaskets and studs? '90 1.8 corrado,  found it on autohausaz.com but they don't have the studs.

[jimfoo]

Yes, they have to if it hasn't been replaced before. I have a 1987 Rover with a gas tank recall which I know hasn't been fixed, and I know they have to replace my tank if I ask them. I asked a friend who was the service manager at the dealership.

I'm 99% sure if your vehicle has a recall then the dealer has to do it no matter what.
You could even ask them over the phone if you vehicle has any open recalls.