[Vwdiesel] 1.6L TD rebuild: hints?

Gary Shea shea at gtsdesign.com
Wed Sep 17 13:18:24 EDT 2003

I'm rebuilding a 1.6L TD, it's at the machine shop now.  Gonna take the
big hit for new pistons (cylinder wear is at 7-10 thou).  I'm planning
on new rod bushings and bearings, and new main bearings.  The crank has
a nasty groove ground in it on one of the mains.  If the groove is too
deep to grind out without replacing the crank, any idea of what will
happen if I just ignore it?

I don't want to get into "replace everything" mode, but I'm wondering if
there are any known trouble spots that I should be doing something
about.  For instance, is there any reason to replace the oil pump?  On
the 2.0L type iv engine that's standard practice for a rebuild.

I've got new valve guides, will try to press out the old ones and press
the new ones in.  I seem to recall that someone else had done this
without special reamers and such.  I'm planning on hand-lapping the

Advice appreciated!



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