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Old 27-08-2010, 08:10 PM   #1
CHR15_W
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MK1 Golf GTI - Engine Detailing

I have a 1990 Golf Cabrio GTI which I have owned for over 11 years. Just over two years ago I had the engine rebuilt with a few mods:

Rebored engine block 1.9
Ported and polished cylinder head
Newman fast road cam
Vernier cam pulley

The block had been painted with some red paint stuff and it's all flaking off! Also the gearbox is on it's way out the usual crunching from first to second.


So this is the plan:

Remove engine
Complete engine & bay detailing
Have gearbox rebuilt professionally
Refit engine


So this is how she looks at the moment.



After stripdown



Engine out







Removing the clutch pressure plate



Then onto engine stand



Engine bay degreased



After a couple of hours the block now looks like this





The block is degreased & metal prep



Just painted in high temp paint



Masking tape off




Last edited by CHR15_W; 27-08-2010 at 11:25 PM.
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Old 27-08-2010, 09:51 PM   #2
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Awesome work! I wish I had the know-how, the time and the tools to do that to all my cars. What a refresh!
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Old 27-08-2010, 10:16 PM   #3
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Thanks for the comment!

Some of the parts taken off have been sandblasted then painted in satin black



Close-up of the finish



Radiator cowling completely stripped, painted and reassembled



New warning sticker applied



Radiator fan cleaned and painted, then replacement sticker applied



Starter motor cleaned up, painted and reassembled. Look like new again!

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Old 27-08-2010, 10:34 PM   #4
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looks like your doing a good job but on a more important note

You have a radiator and carpet in your garage ?
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Old 27-08-2010, 10:46 PM   #5
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I have a radiator but no carpet sadly!

Cleaned up some of the aluminum part to remove the oxide, then a couple of light coats of aluminum spray.










Water pump ready to be reassembled cleaned up and painted







Air flow sensor refinished

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Old 27-08-2010, 11:15 PM   #6
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Stripped down, cleaned and painted brake servo and linkages











Sandblasted engine mount bracket then sprayed in satin black and new engine mount rubber pressed in

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Old 28-08-2010, 01:56 AM   #7
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Just in case

Make sure you have no sand in the gauze of the rocker header's built in breather.

Ideally you need to drill out the spot welds of the metal plate inside to be able to take out the gauze, burn it with a flame to clean it and reassemble, with fresh tack welds on the cover plate on the inside of the rocker cover.

You don't want sand going around your new engine, or alternatively, buy a new rocker cover.

HTH.
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Old 28-08-2010, 02:14 AM   #8
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looks mint!
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Old 28-08-2010, 08:01 AM   #9
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Lovely work, that is going to look superb. I am loving your attention to detail. On a purely practical note would a new water pump be worth the money now?
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Old 28-08-2010, 08:33 AM   #10
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Thanks for the comments guys. The rocker cover was cleaned up with a wire brush on a high speed drill. I didn't sandblast that part because of the built in breather.
The water pump is only about 12 months old, so just needed cleaning up.

Another update!

Some genuine parts ordered




Engine block waiting for the rebuilt head to be fitted




I bought a Zinc plating and Blackener kit to duplicate the original finish on the bolts and brackets for aesthetic and corrosion resistance.



Here are the yellow zinc parts





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