2011 VW GTI top end rebuild

[clgodwin79]

This is what derailed my 1995 K1500 build.

It’s a 2011 Volkswagen GTI. 2.0 turbo 6 speed car.

I got it for $2k because the previous owner failed to address the known bad factory timing chain tensioner. So it jumped timing. And since it’s an interference engine, the intake valves got into a fight with the tops of the pistons, but lost the battle! Lol

I bought a VW reman head and replaced a lot of other things along the way.

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Of course I towed it with my Silverado!

 

[clgodwin79]

Lots of new parts!!

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[clgodwin79]

And more parts!! Plus lots of new tools. German vehicles don’t use many regular metric head bolts. Mostly torx and something called triple squares.

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The engine before disassembly

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[clgodwin79]

Starting tear down

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[97C1500TJ]

I have a secret love for VWs. My first timing belt job was on a 1.8 Turbo. I always get a kick out of the guys that reuse their 100K mile tensioners on interference motors. I’d pay the cost of an OEM one to save me from fixing what a broken one causes.

 

[clgodwin79]

Head off. You can see where ALL of the intake valves were bent from hitting the pistons. Also I had to extract and replace all of the downpipe exhaust bolts. That was less than fun!!

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Lots of carbon on these direct injection engines! I cleaned up the pistons. But since it was a new head with new valves I didn’t have to worry about them!

 

[clgodwin79]

Cleaned up cylinders and pistons. Replaced factory plastic water pump with an aluminum one. New turbo downpipe exhaust studs.

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[clgodwin79]

New head one. Cleaning up and resealing the direct injection fuel injectors. Cams in, and figuring out how to time the chains and set them all up correctly.

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[clgodwin79]

Timing chains good to go. Fuel injectors back in. Torqued crank bolt to 1 million neuton meters! Dropped oil pan to check for metal shavings. There were none, so cleaned and reinstalled. Cleaned up massive amounts of oil and road grime. It had definitely been tarred and feathered! Almost done!

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[HotWheelsBurban]

Looks incredibly complicated, glad you got it figured out!