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Old 12-29-2017, 08:36 PM   #57
GreggGTI
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Machine shop hasn't touched it yet. So, long weekend means Tuesday at the earliest. Whatever...... I'll stop ignoring the family for a few days!
So, now that I have a little time I've created a 'seeking K04' ad to see if there are any out there for the right price. I'll give it a few days to see. Anyone have any insight????? Otherwise, no updates until then!
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Old 12-30-2017, 01:38 AM   #58
Carlosfandango
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Iíve not heard of any of the new revision tensioners failing (regardless of generation), this is probably due to wire locking mechanism that can be seen at the base of the piston, itís like a fail safe! It will not allow the piston to ever retract back further than the originally fitted depth, so basically it doesnít rely on oil pressure like the old revision so wonít slacken.


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Old 12-30-2017, 01:42 AM   #59
Short Bus
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Man, great work. I came in to say that at this point with my car if the engine goes I'll be installing another. Even if I pay someone $7,000 or $8,000 to do it for me I absolutely cannot find something else for that amount of money that I would enjoy as much. Just poking through this thread kind of makes me want to go find a cheap, highly used engine to take apart and put back together again for fun.
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Old 01-02-2018, 01:33 PM   #60
damagi123
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Quote:
Originally Posted by GreggGTI View Post
Machine shop hasn't touched it yet. So, long weekend means Tuesday at the earliest. Whatever...... I'll stop ignoring the family for a few days!
So, now that I have a little time I've created a 'seeking K04' ad to see if there are any out there for the right price. I'll give it a few days to see. Anyone have any insight????? Otherwise, no updates until then!
glad you're deciding to go that route
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Old 01-02-2018, 11:16 PM   #61
GreggGTI
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Quote:
glad you're deciding to go that route
Probably not in the cards. It's a fantastic upgrade and I was offered a used, 8k mile K04 for $1000, however the mandatory software upgrade at $899 from APR put the brakes on that. Not to mention a recommended exhaust and intake upgrade. So while it's a great price per horsepower upgrade, $1900 right now is pretty rough to justify. Unless I'm missing something? Sucks to not do it though!

Motor is still at the machine shop. Guy wants to take the heads off in order to drill in and remove the sheared stud/broken off extractor. I am not going that route, no need to take the heads off. I'm going to take my time with a Dremel and some stone bits to grind the entire thing out. Not scared, Jalopnik covered a very similar scenario https://thegarage.jalopnik.com/heres...fro-1746998630

Just need to go back and get the motor. 6 days now, for nothing? That's how these things go! Hopefully more to come tomorrow.
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Old 01-03-2018, 11:10 AM   #62
lukesGTI
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Happy you decided to go this route and following your thread closely.. Did your motor experience any symptoms before failing?
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Old 01-03-2018, 11:21 PM   #63
GreggGTI
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We're back! Went and picked up the motor after the shop said 'take the head off and bring it in'. No thanks, not easy or cheap! I can do this. Spent hours grinding and drilling out the carbide extractor and stud. After several bits and grinding pins, I got it down pretty deep! I wasn't perfectly on center, so it got interesting in the end. Had to tap it to 5/8 size since the M8 was drilled out and the tap wouldn't bite. I was just plain out of options. Helicoil is a big question mark, and I didn't have a stud big enough. So, what you see is an SAE 5/8 Bolt middle finger to German engineering! I'm all for originality, but this just works! Torqued is down to 18 ft/lbs perfectly. So glad to have a solution that didn't cost a thing, other than some beers for my buddies helping me.

Here is the sheared stud, deep and showing a little drilling. The extractor is on the right side, hard to see but it's in there and wasn't coming out!





Turbo is ON!!!!



Quote:
Did your motor experience any symptoms before failing?
Actually, yes it did. Let me preface this statement with the fact that I drove a 2003 S8 for a year with a failing tensioner that clacked at start-up for 1.5 seconds. Extremely common to that car and by no means a deal breaker, something I thought nothing of. So the noise was familiar. I mistakenly assumed the tensioner in the GTI was bad, but given my experience it wouldn't kill the car! So, it clanged for a week before failing on shutdown. After that, it would not restart for me, and the rest is history....
Attached Images
File Type: jpg Shear1.jpg (296.1 KB, 297 views)
File Type: jpg Grind1.jpg (255.0 KB, 294 views)
File Type: jpg Bolt1.jpg (362.0 KB, 288 views)

Last edited by GreggGTI; 01-04-2018 at 01:06 AM.
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Old 01-04-2018, 09:13 PM   #64
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Looks good, nothing wrong with a "jerry rig" that works!!

Its just amazing you took this job on, and watching you do it all with your shared pics and all is very cool....Keep us posted.


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Old 01-07-2018, 08:03 PM   #65
GreggGTI
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Hey again. Transmission and motor have been mated together and torqued down. Alternator and compressor attached. Hoses attached and the motor has been reinstalled. Now just to reconnect the downpipe, cv joints and plug in the electricals and radiator and push the go button! That will be nerve wracking. I hope to have most of it wrapped up tomorrow, stay tuned!


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Old 01-07-2018, 11:13 PM   #66
Short Bus
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Whoa, now that's "easy" access. I looked up how much work it is to pull all that off the front, any particular reason you went that route instead of dropping it from the bottom?
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Old 01-08-2018, 09:51 AM   #67
GreggGTI
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Mostly because I don't have a lift, or any way other than jack stands to raise the front end up enough to sneak it out. And to be honest, taking the front end off was no big deal. Looks harder than it was.
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Old 01-09-2018, 02:46 PM   #68
Jeffs2013GTI
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So cool you had the nerve to do this yourself. The cost to have this done for sure may have broke the bank.

The fact you tackled this on, never had done this before or anything?

Pretty Cool...




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Old 01-09-2018, 06:30 PM   #69
Doclively79
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In the 20 degree weather the other day my 2012 GTi started dying after a minute of idling and then driving it 30 mph. Then I got camshaft position delay and other camshaft error codes. Cleared those then I got all 4 cylinder misfire codes. Did some trouble shooting and replaced some electrical parts which did nothing. Took it to VW dealer and found out that the spool valve on the camshaft has separated. So there’s a whole list of parts reccomended to replace when this happens and it has 130,000 miles so they want to replace the tensioner (which I already have the new version), timing chain, a bunch of gaskets, brackets etc and it’s gonna cost $4,900 if I let them do it.

Are there any great VW shops in the Austin/Round Rock area that would do a great job and cheaper?
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Old 01-09-2018, 07:32 PM   #70
GreggGTI
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SO CLOSE!!!!

Can't help you Doc, on the other side of the country. I recommend starting a new thread. Or, doing it yourself.....

Got her almost completely buttoned up and ran into a show stopper: Missing a retainer clip for the turbo pressure pipe. I have one for the radiator side, missing the turbo side. VW wanted $5.00 and 2 days to order one. So I made one, came out pretty damn good. Never done anything like this before either, this was cool.



After this, add air intake, battery, oil and antifreeze and hit the 'go' button! Anyone have insight for adding anti-freeze? I don't see a cap. I see the expansion tank, but its small. Also, do I have to bleed the system or will it be okay to just add the minimum amount?



Spent most of my day on my back, looking up and getting dirt in my eyes. Exhaust hook up and CV Joints. I hate CV Joints!
I don't see why tomorrow isn't the day....
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