Complete 1.8t 20V Engine Rebuild ~ Forged Internals and BIG TURBO

In this video I will show you how to completely rebuild a 1.8t 20v Engine from a Vw or Audi. This 1.8t 20v will also be modified with forged connecting rods, forged pistons, and a 1.8t Big Turbo. We will also adjust piston ring gap for high boost. Rebuilt engine will also get a new timing belt, timing chain, and many other 1.8t replacement parts. The 1.8t 20v was found in the VW Jetta, GTI, Golf, Beetle, Passat, Audi TT, Audi A4 and many other VAG cars around the world.
How to Properly Time a 1.8t 20v VW engine ~ • How To PROPERLY Time V...
LiquiMoly Engine Assembly Paste ~ amzn.to/3OU5r0T
Paint Pens ~ amzn.to/3yUhqpF
~~~~ Recommended Tools ~~~~
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Small Impact driver ~ amzn.to/2DZdsMN
Electric ratchet ~ amzn.to/2FydxMS
Magnetic tray ~ amzn.to/2FEpQ6g
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Box wrench set ~ amzn.to/2FzoJch
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Torque Wrench ~ amzn.to/2I7ke5h
Allen Sockets ~ amzn.to/2GlcnAz
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Filmed and Edited by Eli Pastura
~~~~ Playlists ~~~~
Humble Mechanic Podcasts ~ • The Humble Mechanic Po...
Project White Wookie ~ • MK3 VR6 GTI Project Car
Failed VW parts videos ~ • How VW Parts Fail
Tool and Product Reviews ~ • Tool and Product Reviews
How To videos ~ • How To Fix Your Car
MK1 VR6 Swap Videos ~ • VR6 Engine Swap MK1 Ca...
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disclaimer:
The content of this video is available for informational and educational purposes only. It is not intended to be a substitute for the professional advice of a mechanic who has personally inspected your vehicle, nor does it create a relationship of any kind between the Humble Mechanic and you. Every situation may be different, and the Humble Mechanic does not make any warranties, whether express or implied, as to the accuracy, fitness, or applicability of the information or automotive parts portrayed in this video to any project and makes no guarantee of results. The Humble Mechanic and any sponsors of this video will not be liable for any damages related to personal injury, property damage or loss of any kind that may result from the use or reliance on this video and/or any automotive parts represented in this video. You are using the information and automotive parts portrayed in this video solely at your own risk.

[@HumbleMechanic]

Well I hope you guys like long videos HAHA!! Some context about what is also happening here. Last year I bought a $1300 TT with the engine completely disassembled. BUT the pervious owner had bought a ton of upgrades including the rods and pistons you see in the video. There will be a complete TT series coming out as soon as the car is up and running. With the turbo and upgraded parts, we should be around 400HP... Allegedly anyway HAHA!

[@aroundomaha]

I bought a BRZ but can’t quit watching you and DAP. Any update on the Miata? For torque wrenches I prefer the “click” since it reminds me of cracking my knuckles or back.

[@payaso2297]

Where do you guys buy stuff like bearing

[@aleongh]

Hey man, absolutely love your channel and this video in particular! Will you do a 2.0 TSI version if I drive my Mk6 GTI all the way up there from Chile and hang out for a month or two? lol

[@laalaa99stl]

Pervious? Don't be so judgmental, Charles. Also, please consider adding time stamps to your longer videos. You can even edit them into the description after the fact and KZbin will automatically generate chapters based on them.

[@MichaelRCarlson]

I love the long videos! I very much prefer them.

[@erbenton07]

The extra cleaning you are doing is NOT overkill. Its the mark of excellence

[@geniferteal4178]

I remember assembling an engine with my brother. we stopped to have lunch. after lunch we washed our hands before touching the engine again. Not so sure if we washed our hands before lunch. The engine was obviously more important to keep clean.

[@workingclassgarage]

I can only imagine the time and effort that went into this video, mad respect dude.

[@HumbleMechanic]

Thanks brother

[@hondrta]

I was thinking the same thing !

[@notyouraveragegoldenpotato]

Lol. It only takes a couple hours to build a 1.8t from a bare block. I bet it was 4x as long having to record and edit. I've got one of mine on a stand rn. Parts will be here for the weekend (sheared the crank pulley off.. 2nd time and I had even pinned it😂) I've been running Integrated Engineering rifle drilled Tuscany rods for roughly 6 years and they've survived 2 destroyed heads and 2 destroyed blocks (crank shear). Phenominal rods! I'm downsizing the turbo for this iteration because I daily drive it and the big full frame turbos suuuuuck for daily driving a manual in mountains

[@lightskinantics4200]

@@HumbleMechanic great work !

[@lightskinantics4200]

@@notyouraveragegoldenpotato what would you rate reliability?

[@ashes_s3928]

wow, literally the perfect video for me rn, was just getting the urge to go bigger turbo on my mk4 gti lmaoo i love the synergies of life sometimes! keep it up charles!

[@HumbleMechanic]

AWESOME!

[@Lord_Verminaard]

I've built about a dozen VW engines now, and I never get bored watching someone else build one! Also good to know that my best practices match yours during assembly... Looks great, it should be a runner for sure!

[@viperfukgoogplus386]

Glad I can't say the same. I don't own a VW so I only had to built mine once.😂

[@Lord_Verminaard]

@@viperfukgoogplus386 None of the VW engines I built have needed rebuilt yet, one of them is on 375,000 miles and climbing. I build them for customers along with my own projects.

[@1Cobranut]

Always record your rod bolt free lengths before installation, that way you can reuse them if they're not permanently stretched. Also, you can install the stretch gauge over a long box end wrench, and read the stretch directly as you tighten them.

[@therocinante3443]

A person could learn to be an engine mechanic from this one single video. Much respect, dude. You're amazing.

[@actng]

i have a MK4 GTI 1.8T and it's awesome to have guys like you still working on older engines / vehicles like this!!

[@miketeeveedub5779]

Awesome video Charles! The one hour flew by in an instant! You kept the conversation light and lively and not overly technical to bore us. I look forward to part 2 to flesh out the rest of the build and firing up that bad boy! Cheers!

[@kennethd7048]

Hey there Charles, always appreciate your videos. I have to say, this is your best one so far. How you take the time to carefully explain everything is to your credit. your friend, volvo snob.

[@HumbleMechanic]

Thank you so much!!!

[@George-zq2sk]

Charles can i say how much I love these detailed Mk4 builds!! This makes my weekend! The level of detail is epic as always

[@stevebarnette]

What a wealth of knowledge from an awesome person. You kept me glued to the build from start to finish. In awe throughout the video. Thank you.

[@kashifchand3933]

Much respect. You told us the even minor details which often people forget while assembling the engine. Keep up making great videos. The car owners who come are really blessed by your great effort n attention which needed to roll there cars in next many many years.

[@nickmitton7350]

Love watching engine rebuilds. Brilliantly done sir.😎👍

[@fesa_performance9617]

I do not comment often. but this is an insanely good video. Great dude, great knowledge and a evem better video. I like your extra cleaning etc... THIS is real engine-building like every engine should be build

[@hondrta]

I LOVE long videos from you. Your demeanor and intelligence and HUMBLENESS make you a great guy to watch and learn from.

[@AlisterRobbie]

Well played bloke. Fantastic build. I'm not at the stage where i'm keen to pull my 1.8t out of my A4, but fascinating to see the level of detail that goes into the build. Keen to see this when it's all buttoned up and running.

[@jameshaulenbeek5931]

Very cool to see this! The EMD locomotive engines I work on have piston oil squirters as well - both for cooling and lubricating the piston thrust washer. The pistons in the EMD engines are a floating design so they'll rotate inside the cylinder in order to increase the piston life and prevent excessive wear in one area. Edit: as a side note, I've had to loosen the end cam cap to remove an old cam seal while doing a timing belt job - if you're fighting a seal and you can easily access the cap bolts, totally worth it to make the job easier.

[@xXYannuschXx]

The 1.8t was such an amazing engine, I had the 224hp BAM one in my 2004 Seat Leon Cupra R. Ran very smooth, had tons of power even at low rpm (you only needed 6th gear on the Autobahn) and it was always fun to mess with luxury car owners, that bought the smallest engine and then got smoked by a 16 year old spanish car.

[@tylerpadrao1566]

I just picked up a project MK4 GLI with the 1.8T. This is a very informational video. I'm sure I will be watching many more of your videos. Thanks Charles!

[@noticeablystrange3021]

This literally could not have come at a better time. My 1.8t is at the machine shop getting all fixed polished up and ready for my build.

[@archipiphanyworkshop860]

Great video. I’ve been doing a ton of research on assembling this engine and you’ve hit every nail on the head. A thoroughly enjoyable video. Great job!!

[@lmao5125]

You are truly a Bob Ross of engine assembling process❤

[@HumbleMechanic]

this is my favorite comment in a long time! THANK YOU!

[@bayareaclassicscom]

Your videos are not just entertaining, but also very informative and thorough. Thanks! I believe you answered the questions faster than O could think of them lol.

[@nicolas6820]

i could watch you assemble engines all day long man, flawless work!

[@tedbear631]

This was awesome can't wait to see the rest of the build!

[@RadsGarage]

Super useful! Thanks so much for putting it all together into one clear and concise video! Now lets just hope I can replicate this.

[@scottcates]

You can do it.

[@dylanwood8235]

i have never rebuilt an engine before but watching this was great you kept it interesting and I learned so much. Thank you .

[@Spaceman6400-]

So much knowledge and experience required to do this stuff. Awesome to watch, thank you! I had one of these Audi TT Roadsters when i was a young dude, loved the 1,8t, but a bigger turbo cant hurt :)

[@CarChris82]

Love it mate thank you🙏by far the best guide on youtube👍🏻 planning on forging mine and putting a different turbo on my tt

[@1crazypj]

I guess you pay someone to do your engines? That may have been entertainment but it wasn't the best guide by a long shot. There was so much 'wrong' it wasn't funny He did mention later that the rings have a 'top and bottom' face, the second ring is also secondary oil control and is a Napier design (originally on aircraft piston engines, 1930's probably) Personally I haven't been a fan of Wiseco pistons since the 1980's, they use a 'soft' high expansion alloy which requires very large piston to cylinder clearance. Mahle have a proprietary blend they developed with Porsche for forged pistons which has much lower expansion rate (so 'tighter' cylinder to piston clearance, usually close to stock cast piston ) but it is more expensive

[@rainvillecreative5410]

One thing I did on my last engine build was I had the ring gaps checked with a torque plate on. As most builders know they use these for boring the cylinders so they're the right size, because apparently the cylinders can change up to .001" in diameter. However the circumference of the cylinder (and thus ring gap) changes by .003" for every .001" of diameter change (because C = 3.14 D), which is not insignificant.

[@mobaj1147]

Bro I took my a4 1.8 out 6 years ago... now u got me contemplating get back to rebuilding it with this guide. God bless u.

[@focusracer19]

I dont currently have a VW or Audi but do enjoy watching the channel, its really informative and I learned alot. I had no idea what setting ring gaps was so thanks alot for showing what it is and how to do it! Nothings more annoying than watching a video and having someone say make sure you do xyz but never showing how to do it.

[@AggelosT]

Hey Charles, here in Hellas Europe when we change the Dual mass flywheel with Single mass flywheel the flywheel comes with bolts with hex head because the triple square bolt heads are very tall and the clutch disk "grind" to them. Thanks for the very detailed video 🙂🙂

[@joshuabaldwin3490]

The bolts used for single mass conversions on our kits here are often the stock bolts from a MK3 affirm 1.9 TDI (AHU, etc) Obviously a ton of other applications too, but that's the one that comes to mind :) Just a good tidbit if anyone else comes across this comment :)

[@Aesthention]

I can't believe I just spent an hour watching an engine rebuild for an engine I don't even own ...

[@everyhandletaken]

You're not alone lol

[@chaos1291975]

you asked about the sound of the torque wrench . i just got my first digital one and i have to say i would never go back i love the sound and the adjustments are so much easier . its like a carpenter going from a hand held hammer to a nail gun lol . loved the video thanks for going into so much detail i loved it

[@seemelater5056]

i watched 58 mins of a guy mounting an engine and i didn't for a second think about anything... this was the best hour i ever spent honestly, great to find a channel where to pass time not wasted (i learned a lot)

[@8gti9]

Nice build 👌 very educational, I thoroughly enjoyed the video.

[@1crazypj]

except the piston measuring and ring 'selection' was so bad it was painful to watch.

[@Mikefngarage]

GREAT VIDEO 1.8 T.......Awesome powerhouse

[@georgecollins2347]

In the future I plan to build my a3. I will just chuck a set of rods in but this video is a massive relief as a source of information. Thankyou for the video! Took ages I bet! Thankyou

[@omarrama92]

I rarely rarely watch videos like 30 mins or longer, but Charles, your videos no matter how long they are I can watch every second of it, and enjoy it. I actually probably learned a lot of new stuff just from this almost hour long video. Keep up the great work!

[@Mikefngarage]

Badass H rods!

[@dicknodnfs]

I've wanted to see a rebuild of this engine, because at 204K and the second timing change recently, the internals on my GTI might be getting tired. I have the AWD version and looking at your process it's of course complex but not any more complex than a recent rebuild of a Chevy 283 I saw on Hagerty. You can watch these videos back-to-back and only see the different engine design between the two companies. They are virtually alike step by step during the build. The process is the only difference between the makes. This video dispels the notion that because it's Volkswagen, the complexity is higher. Now all you need is the plaque that says, "built by Charles AKA Klaus". Many thanks.

[@xXYannuschXx]

At 204k the internals should still be top notch, my 224hp BAM 1.8t at 170k was still a lot of trouble for cars with similar hp. Most likely the boost solenoid has worn, or the injector seals have gone bad. The camshaft adjuster also likes to fail on these engines, especially the ones on the 180hp versions.

[@Ahagmann855]

Love build videos, especially when they are as detailed as this one 😊 Lost of tips and tricks👍🏻

[@HouseCallAutoRepair]

Those are so much fun! A friend loved to buy A4's that needed massive amounts of rebuilding!

[@chacehahn6556]

Did you make a parts list/ parts overview for this build? I am going to be doing this EXACT same thing on my TT and a full cost breakdown and parts list would be immensely helpful. I cannot find any full lists online and I have put together my own list but am not sure if I’m missing anything

[@gabrielstaniszewski8933]

did you do it? you have a list?😅

[@Mikefngarage]

definitely want those piston squirters good. they keep the bottom of the pistons cool for the turbo boost. And if one is leaking like that it will make the oil pressure really low. Maybe that is why it spun a bearing?

[@imakedookie]

yeah that sounds non issue, sorry. even with the spring broken it would only flow a bit more than the others; oil pressure mightve dropped more through it but i dont see it as being enough to spin a bearing. im thinking either high-load and cornering at a lower than full oil level (like it had been burning oil for a little while) and starving the system that way, or literally just not changing the oil enough to the point it was diluted or degraded and drop in viscosity = drop in pressure. something had been wrong for long enough to produce this failure.

[@Mikefngarage]

@@imakedookie yea I guess that would depend on the volume of the oil pump. That squirter seems to me to be a pretty big leak. and unfortunately they dont have a running pressure on the car. at least mine dont. they only have a low pressure switch which is a very low bar amount. So you would not know weather there was low oil pressure till it was way too late.

[@imakedookie]

@@Mikefngarage that is a shame and a half! it would help to add a port from factory that sends a signal direct to ecu, should be standard!

[@sullivanburnsworth2286]

Great video for your fellow ocd mechanics. The easiest to follow video I’ve ever watched.

[@gageharris2502]

Love your videos man seriously thank you 🙏🏼 great step by step videos makes things 10x easier for guys like me that don’t know what they’re doing😅

[@wiking-th1sh]

Hello, many thanks for one of your professional video about our engines. In my opinion, probably the best and comprehensive video on how to assemble an engine and with very good advice and educational explanations. You become captivated by watching the same video over and over again. In short, "Top of the line" on the web. Highly recommended.

[@otonielaburtobermejo4774]

This gives me confidence as I prepare to build my 2013 genesis coupe 2.0t( I know, not relevant) but your videos are just so awesome!! 😎 I'm soaking up all the information available 😁

[@Jhonnynova]

Can't thank you enough for putting out this video. Sure there's rebuild info on this motor already on KZbin. But not the humble mechanic way!. I have my 04' GLI sitting waiting for my first rebuild. It's people like you that can help me achieve my rebuild goal

[@HumbleMechanic]

David this comment made my day!!

[@jawk007]

this video is awsome, as a early student on carmechanics this makes everything come to light so easy

[@chacehahn6556]

This is perfect!!!! thank you so much! i have a TT 225 that im working towards doing this on! your R32 haldex and rear end dissasembly video helped me SOO much with my car and this one is a godsend as well!

[@tripleh3195]

Watching you put the sealant on the oil pan sped up was extremely satisfying. 20/10 highly recommend!

[@HumbleMechanic]

Thank you!

[@daveblais4019]

I love the box trick with the "peggy hooks". Never seen or thought about that before!

[@xNachoPandaXx]

literally just finished watching the video, great content as always!!! giving motivation to build my TT's Engine!!!!

[@acefighterpilot]

I know I'm late to this one Charles, but this was a great way of unwinding after having to work on the weekend. After this I almost feel like I spent the whole weekend fishing.

[@TurtleVerified]

As someone with two Mk4 Jettas, I've watched this video three times... And will probably watch it again as I breakdown and rebuild the GLI... THANK YOU for this video. I'm NC if you want to help; but you already have the content so..... lol

[@james6331]

Great timing, currently rebuilding the engine for my 25th Anniversary GTI.

[@arturg5854]

I love these in depth engine rebuild type videos. I have always wanted to rebuild an engine but have never been brave enough to try. Maybe I will build a 1.8t like this one to swap into my 944 some day lol.

[@vwjetta4138]

944 gang

[@Halfrightfox]

Videos like this is why Humble Mechanic will go down as the the best automotive mechanic in history.

[@rbr333_]

love it how you make it look soo easy and calming. bob ross of engine builders

[@wafi3187]

I can put 1.8t together with my eyes closed but still I watch this video whenever I’m bored.

[@peterreid8767]

Awesome video - thanks for taking the time to pull it all together!

[@zuhlera]

I have this engine on my tt and it’s probably the most reliable engine on a Audi/VW I ever had I love it and I like how high power it can make

[@Manuel-gs9hw]

I am just now learning about engines. Thank you for your video, you did a great job!

[@flaviopereira4572]

love the content brother! the only thing i think the channel miss is you puting a playlist just working on engines love from UK

[@pkf4124]

Bookmarking this for when l do the strip down on mine, only ever done 8v Vws so handy to know the slight differences when building a 1.8T

[@TdrSld]

Humble, engine builder here. If you're going to use the piston it self to line up the ring for gapping. It's best practices to put the oil scrapper ring on the piston, if you don't there is enough play between the piston and cylinder wall to "tilt" the ring just a little and it will make the gap out a thou or so (tight when put in parallel). Buy placing the oil scrapper ring on the piston it lets the ring land square up the ring to the bore. I have a plastic tool for this that makes its easier and faster as you're not fighting a whole piston and or rod. Love the build.

[@mddenis1]

It was so satisfying to watch you assembled this engine

[@yuno3364]

I'm not a volkswagen guy, but I can't help but watch every video you make. Keep up the good work! I learn so much

[@HumbleMechanic]

Thank you so much

[@yuno3364]

@@HumbleMechanic Ive built a few engines, but the Cams and Timing Chains on VW concern me so much, but you make it look easy.

[@lincolnbothang7258]

I loved this video, thanks for taking your time to work and show us how to do all this. I will be doing this in the future thanks to you.

[@saarekas8177]

Blew my s3 engine few days ago, probably went lean and burnt a piston, soo that video will help me alot bc it's going to be my first rebuild

[@k22163939]

1.8T never lose!!!!!! Great work and thanks for the share ~

[@s.o.s.exploration2412]

Love my 2004 AWM 1.8T with 5speed manual trans. Saving this for future. Rite now after 150k the coolant temp sensor has finally started acting sketchy. Never had a leaking issue because the person who worked on it last used high temp gasket maker so I'm gonna carefully do the same. That's a long time with no issues and no leaking from that common issue.

[@nelashharinarain3394]

A true genius at work. Just loved the video. Keep up the excellent work

[@angusstewart8686]

Man this is a great video I have a 2015 passat (1.8t with 6 speed dsg) and I thought of getting a "better" car but I really love this one, plus I can get 24 8' 2x4s in it with the trunk closed. Doing an overhaul and turbo upgrade and some tuning and I think I could have a passateratti in a reasonable time frame only 120000km on it. Man, thank you for this video a real pleasure to watch great form bud.

[@CorradoAlley]

Old Skool build fun, seems like just another day in the 2000s. Good walk through

[@rscottalex]

Love the long video. It may not get you the quick, high views, but you can be sure that it will rise to the top of the list over the next several years for "1.8T Rebuild". You've done the VR6 video, now you need to look for a good 07K 5 cylinder to do the same.

[@hopingforthebest1.9]

That thing is going to be wicked, Ive driven a stock 1.8t car and it was no slouch!

[@BPchamp91]

This video is just perfect!!!! I will be fallowin this video play by play when I build my 2006 Audi A4 6sp USP. Unfortunately will only be K04-15 for now. But I have a precision 5831 that will be thrown in down the road Thank you for the great videos!!

[@izzyauto6298]

Great video. I've watched this video multiple times and enjoy it every time. Thank you.

[@iminabarrel1862]

This is how you would want any mechanic to work on your engine. Top job

[@neilpk70]

Your videos are informative, and a hell of a lot of fun to watch!😃

[@AE-so6mx]

Awesome, thank you for this video! I am extremely interested in more of this tt build.

[@peterboffa7264]

Dude I’ve had such a fun day watching your videos. Thanks

[@maxpeck4154]

I owned a MK4 2003 Jetta with this exact engine (AWP) and did the timing belt job at about 65,000 miles and replaced the water pump with the euro spec metal impeller version. For me personally it was peace of mind regardless of how good the current plastic ones are. This was a great watch - I had that car for 11 years and aside from 2 coil failures and a blown turbo I never had an issue with the engine itself. Still miss that car

[@JaimieSigamoney]

This is world class engine assembly content 💯 thank you for your time and effort 🤝🏽 just looking at your work I would love to purchase a built engine from you.

[@przemysaworszulik3865]

I have this one in my Škoda Superb 1.gen. - such a great engine!

[@nickmaniapen]

Your videos are super helpful! Thank you for making them.

[@Goonit83]

I’ve got one of these engines AEB, with all the bits to fit ready to put in my mk1 golf. Great video bro. Love your channel 🍻 🇦🇺

[@CraigMansfield]

I like your style, man! I love your attention to detail and your care.

[@diegojaviersalinas]

Funny I'm not a mechanic and yet I find so satisfying to watch your work, specially on this video that you are just working on the engine of my Passat ha ha

[@WouterB76]

Very detailed, good educational video! Thanks Charles.

[@papaarmo5028]

That's one of my favorite 1.8t blocks AWP for the win

[@LondonLawBreaker]

Excellent video. Thanks for that! It also passed the doze test…I didn’t nod off once

[@danielmarshall4587]

The "twe-hey-valve-ter-bow" oh yes many many of those here in the UK too. As you say fitted to loads of different models Audi Seat Skoda VW, and lots of after market "replacement"(upgradeable) parts avaliable. ANYHOW I'll sit down and enjoy your video thank you so much for your time and effort bringing us this vid.

[@danielmarshall4587]

When the geeza working on your car talks about what he's doing as "this may not really be necessary"..... THAT'S THE MAN TO HAVE WORKING ON YOUR CAR, STUFF....fill in the blank.

[@UberWagen]

Just got a free AEB. Finally going to go turbo for my Scirocco, this will come in handy!

[@jamesk3565]

I waited until I got out of work and got home to watch this. this was very therapeutic 😊. I'm one of those wierd people that torque EVERYTHING, including drain plugs🙃

[@JasonLuther1]

I enjoy the long form videos. Great work man