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We decided to blog a rods install for a 03 Jetta 1.8t. To complete this project you need the following parts. Rods.. We choose intergrated, Head gasket, Cam gasket, Valve cover gasket, Gooseneck.. Common failing item - it will be off anyway, New Coolant, Oil and filter.. conventional oil for break in, Rod bearings.. You must get the older AWD bearings for this job. Intergrated failed to tell us this when ordering so it set us back a day. You need the ones with the stop tab, Piston Ring Set, Oil Pan sealer.
First things first remove air intake, Coil packs, Upper timing cover, Unbolt the upper charge pipe and remove the Rubber 90 and push the charge pipe back. One of the hardest things to do on this job is get the intake out of the Turbo inlet pipe.. Where the rubber meets aluminum, Its almost always stuck. Lots of spray lube and lots of muscle may be needed to lift it out. Remove the intake manifold bolts and nuts, Remove the clamp and boot from the throttle body. Pull Intake forward, Not out. metal fuel lines and injector harness can stay right on the intake. Remove the three upper turbo bolts with 17mm wrench or socket. Remove the cam pulley center bolt and Just slide cam sprocket off the cam You ll be doing the timing later any way. Remove the gooseneck and egr valve from side of head, leaving hanging in this area. Remove the valve cover , and head bolts. Lift the head off the block. After lifting the head we noticed the area where the Piston rings do not touch needed to be cleaned up. We decided this Blueberry Flex hone would do the job. And it did perfectly. We decided to hone the cylinders with the pistons in and down. This way we didnt risk getting debris on the crank shaft and it was an easy clean up process. This picture is after the cylinder walls were touched up. Next step is to raise the vehicle, Drop the oil pan and remove the oil pick up tube. The actual pump can stay on the motor. Then your ready to loosen and remove the rod bolts and push the piston/ rod assemblies up and out of the block. With the cylinder head on the bench now is a great time to replace the cam tensioner seal and gasket, because it is such a common leak. Next thing to do is pull out one package of Piston rings and measure the piston gap. Seen here Then you need to clean all the carbon off the pistons and use old rings to clean out the piston ring grooves. Heres a picture of the new rings installed. Im not going to talk about specs because you should have a manual for that. Heres the pistons installed and head gasket installed. Heres the lower end pic with rods installed. And a final picture. Dont forget the timing belt gets removed during all of this and should be replaced with new if it hasnt been done in a while. It runs!
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