The machine of a Dream!

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The machine of a Dream!

Postby kylebassani » Wed Aug 16, 2017 11:44 am

Hi guys,

I need some help.

Here is some background
I recently purchased a mk2 jetta cli with the 1.8 16v kr motor for a very good deal :hurray: knowing there would be some work to be done on the car.
So after getting the car home, I started doing the major assessments on the condition of the car and ultimately decided to pull out the motor, clean up the engine bay, strip the motor and replace all the seals and gaskets and assess the internals.

So after pulling out the motor I noticed there is a crack on the block :bang: :bang: :bang:
I proceeded to strip the motor to find that the internals are in great condition, new pistons, new oil pump, new water pump, seals look great, head gasket was still good etc.

So for my issue, I want to know can I get the block repaired and where can I find a trusted workshop/engineering shop to do this?
With finding all the internals in such a great state I really do not want to risk buying another block to now have to bore it out due to condition, meaning pistons will need to be replaced.
If sourcing another block is the only option, can I look for any block ex. a block from a 8v 1.8 motor etc.

Thanks in advance for the help.
Last edited by kylebassani on Wed Oct 25, 2017 9:12 am, edited 2 times in total.

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Re: Nasty surprise!!

Postby BlueBlob » Wed Aug 16, 2017 11:52 am

How/where is it cracked?

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Re: Nasty surprise!!

Postby panic-mechanic » Wed Aug 16, 2017 12:25 pm

Picture yes but any proper engineering or welding specialist should be able to sort that out. Down th road from you is east rand automotive engineering or if younwant a welder then spartan area try aero tig
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Re: Nasty surprise!!

Postby kylebassani » Wed Aug 16, 2017 6:24 pm

Thanks guys appreciate the help

Here are the pictures, you can see that the PO did try to fix it.

Here is the inside, looks like a conrod hit it
Image

Here is the outside
Image

Also you can see it hit the oil nozzle, not to sure what the correct term for this is...still need to check if it is clear.
Image

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Re: Nasty surprise!!

Postby THANAS » Wed Aug 16, 2017 6:33 pm

Rod through the block for sure. It took out an oil squirter on the way out as well.
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Re: Nasty surprise!!

Postby BlueBlob » Wed Aug 16, 2017 6:57 pm

Is that squirter glued/epoxied in there? :0

That's going to make honing it properly oodles of fun

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Re: Nasty surprise!!

Postby PapaJo » Thu Aug 17, 2017 2:39 am

Wow, that is a nasty surprise!!!

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Re: Nasty surprise!!

Postby Unobeat » Thu Aug 17, 2017 7:18 am

Ouch

That is not a good surprise, tooo nasty.

Just the thought of buying and only to find that you need to drop the motor cause something did not feel right and then boom there is a nasty surprise.

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Re: Nasty surprise!!

Postby kylebassani » Thu Aug 17, 2017 10:42 am

BlueBlob wrote:Is that squirter glued/epoxied in there? :0

That's going to make honing it properly oodles of fun


Not sure what was used, going to try and see if I can figure it out this weekend and also check if it is clear and working...as for honing it, the sleeves look quite good...
Image


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Re: Nasty surprise!!

Postby kylebassani » Thu Aug 17, 2017 10:51 am

PapaJo wrote:Wow, that is a nasty surprise!!!


Yeah, definitely not something I'd wish for anyone...

Unobeat wrote:Ouch

That is not a good surprise, tooo nasty.

Just the thought of buying and only to find that you need to drop the motor cause something did not feel right and then boom there is a nasty surprise.

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It was definitely a motivation killer, found a few other issues as well like only 3 to 4 bolts holding each driveshaft in place!! :fear: :bang:
Agh and I still drove the car home when I went to collect it

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Re: Nasty surprise!!

Postby panic-mechanic » Thu Aug 17, 2017 11:20 am

Even though the bores look good you cannot remove a piston and put it back in without a hone. The rings need to reseat.
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Re: Nasty surprise!!

Postby kylebassani » Thu Aug 17, 2017 11:46 am

panic-mechanic wrote:Even though the bores look good you cannot remove a piston and put it back in without a hone. The rings need to reseat.


Thanks Panic, appreciate it. I was not aware of this, glad I mentioned it...

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Re: Nasty surprise!!

Postby panic-mechanic » Thu Aug 17, 2017 11:59 am

That last picture you posted. Can you see the reflection of the piston top in the bore? That means it has already run in and thus needs to be honed again. Although from an oblique angle you can see the markings it has already knocked the sharp peaks of the hones off.
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Re: Nasty surprise!!

Postby kylebassani » Thu Aug 17, 2017 1:15 pm

panic-mechanic wrote:That last picture you posted. Can you see the reflection of the piston top in the bore? That means it has already run in and thus needs to be honed again. Although from an oblique angle you can see the markings it has already knocked the sharp peaks of the hones off.


Ah okay now I understand, thanks for the explanation. I like being able to answer the why question to things like this.

I do not need to replace rings though?
Or should I rather do it?

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Re: Nasty surprise!!

Postby THANAS » Thu Aug 17, 2017 1:29 pm

New rings and a hone is a must.
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Re: Nasty surprise!!

Postby BlueBlob » Thu Aug 17, 2017 1:30 pm

kylebassani wrote:
panic-mechanic wrote:That last picture you posted. Can you see the reflection of the piston top in the bore? That means it has already run in and thus needs to be honed again. Although from an oblique angle you can see the markings it has already knocked the sharp peaks of the hones off.


Ah okay now I understand, thanks for the explanation. I like being able to answer the why question to things like this.

I do not need to replace rings though?
Or should I rather do it?


At this point, you would be wasting a lot of time and effort not doing a proper rebuild. Rings, bearings, the lot.

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Re: Nasty surprise!!

Postby panic-mechanic » Thu Aug 17, 2017 2:04 pm

Look on a serious budget sure reuse rings that has very limited km on it but you have to hone. I Personally prefer to use new rings specially if you don't know the history.
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Re: Nasty surprise!!

Postby kylebassani » Thu Aug 17, 2017 4:31 pm

BlueBlob wrote:
kylebassani wrote:
panic-mechanic wrote:That last picture you posted. Can you see the reflection of the piston top in the bore? That means it has already run in and thus needs to be honed again. Although from an oblique angle you can see the markings it has already knocked the sharp peaks of the hones off.


Ah okay now I understand, thanks for the explanation. I like being able to answer the why question to things like this.

I do not need to replace rings though?
Or should I rather do it?


At this point, you would be wasting a lot of time and effort not doing a proper rebuild. Rings, bearings, the lot.


That is the intention, I want to replace all the seals, bearings, gaskets etc...just wanted to ensure I am not wasting money replacing the rings...does sound like a stupid question the more I think about it

panic-mechanic wrote:Look on a serious budget sure reuse rings that has very limited km on it but you have to hone. I Personally prefer to use new rings specially if you don't know the history.


I must admit I do have a budget but also being a project and I prefer doing something right the first time I'd rather do it now then spend more money in the long run and blowing the budget anyway and probably more so then if I were to do it from the start.

Again guys thanks for the help, it is definitely appreciated and it goes a long way

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Re: Nasty surprise!!

Postby panic-mechanic » Thu Aug 17, 2017 5:37 pm

look rings on those are probably like R800. If they were R4k like on CDL motors I would consider reusing.
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Re: Nasty surprise!!

Postby kylebassani » Fri Aug 18, 2017 1:07 pm

Looks like I might have come right with some Hastings rings...FOR FREE!!! :crazy: :hurray:
And looking at sending in the block next week hopefully :troll:

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Re: Nasty surprise!!

Postby VAG Fan » Fri Aug 18, 2017 1:15 pm

kylebassani wrote:I recently purchased a mk2 jetta cli with the 1.8 16v kr motor for a very good deal


Now, unfortunately, you probably know why the deal was so "very good".

I hope you come right - good luck. (I hate nasty surprises, you have my sympathies.)
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Re: Nasty surprise!!

Postby Donavan » Mon Aug 21, 2017 10:48 am

If it was me I would just replace the block, surely you can get a short block replacement somewhere/or from someone on this forum
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Re: Nasty surprise!!

Postby Killerwatt » Mon Aug 21, 2017 11:02 am

I would rather get a new block as well.
Or at least see how bad the damage is to the oil squirter. If that is epoxy holding it in place then you are pretty much gona redo the motor again when it gives up.
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Re: Nasty surprise!!

Postby kylebassani » Mon Aug 21, 2017 12:26 pm

Donavan wrote:If it was me I would just replace the block, surely you can get a short block replacement somewhere/or from someone on this forum


That was my initial plan, hence the question.

I am just not 100% sure which engine blocks would work, are all the 8v 1.8 blocks the same as the KR block?
Upon initial inspection they do all look the same, I just don't want to deal with another surprise of oh wait you need to do this or that to make it work.

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Re: Nasty surprise!!

Postby kylebassani » Mon Aug 21, 2017 12:29 pm

Killerwatt wrote:I would rather get a new block as well.
Or at least see how bad the damage is to the oil squirter. If that is epoxy holding it in place then you are pretty much gona redo the motor again when it gives up.


I am hoping to answer the question around the squirter soon.

I still have the block to see if I cannot maybe source another block first for a reasonable price and condition before sending the block to get it welded up.

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