Replacing the Head Gasket - Any pointers?

[benough]

Got the head back and all looks good.

Just putting it back togther now.

Quick question. With the exhaust manifold, the side with the metal plates, do they go against the head or the manifold?

Also has anyone got any pointers as to how you get the down pipe off the exhaust? I got one to turn but I think the nut was turning with it

[twin eng, twin turbs]

I am getting the head serviced.

The water channels close to the pistons have corroded right up to the piston. That is where, it turns out, the gasket failed, not out on the edges where I initially thought.

Gotta get them welded and grinded so I am getting a head service also.

Also I should have a MK3 Downpipe on Wednesday so I am gonna try and put it back on on Thursday, will keep you posted.

I hope you are dealing with a very experienced engine reconditioner, i have welded heads before with electrolisis in the coolant galleries having reconditioned engines for many years.

The electrolisis needs to be die ground out to clean alluminium before any tig welding is done and die ground again after to the correct port shape, before surface grinding. This is straight forward.

The issue that i must point out and hope that you have had a top notch reconditioner perform the task is the distortion that occurs during the tig welding process. Your head WILL be distorted after welding and MUST be straightened before surface grinding because the cam tunnel will also be distorted! If they have not straightened it before surface grinding the cam will not run concentric with the cam tunnel bores and will not have have any oil clearance and will wear the bores possibly even enough to cause it to lock up! This in turn strips the cam belt at the crank shaft gear and lots of bent valves are the result aswell...

I dont mean to scare you it may be fine aswell...

[benough]

Wow.

Yeah I got recommended to a guy with a good reputation and other people have used him.

At the moment I am stuck on getting the existing downpipe off the cat convertor so I can put the head w/ my new mk3 downpipe in there.

ergh

[aussieg60]

You would have to get a different cat to bolt up to the down pipe too.

[benough]

Well I got told that an exhaust guy will just make me up a new bracket to go between to two

[benough]

Head is on, the timing is done. Just gotta plug/screw it all back together.

Hopefully I can bring it back to life tomorrow night.

[benough]

It lives! Finally got it back together. Had to move the distributor a bit to get the timing right but other than that it works well.

http://www.benough.com/MK2_GTI/start_up.MP4

The down pipe from the mk3 needs an adaptor to be made for the exhaust but other than that she is good to go

[benough]

I have one more thing to bolt on and everything will be apples. It's some sort of temperature sensor that seems to control the radiator fan.

PHOTO

PHOTO

I thought it was the intake manifold but it just kept the fan on

[anarchycamp]

Attach it on the rocker cover under the far right rear nut.