Piston/rod install on our VW GTI MK1 engine for Lemons

This documents the basic engine rebuild we are doing for a 1.8L VW 4 cylinder that is going in our 1980 Plymouth Horizon being prepped for the 24hrs of Lemons. I'm documenting what is happening so my teammates can learn while we are all social distancing.
This video shows how to install the piston rings
Installing the piston/rod into the cylinder
Checking oil clearance
checking and installing the oil pump
What is not shown is the verification of TDC. This cannot be done because it requires the flywheel and the bellhousing from the transmission. I will have to come up with a creative way to do this later.

[@json8172]

Thank you very much for this video.

[@arthurdejager1775]

What pistons are used here? Wall clearance 😮 tell me about the setup please

[@melekk0]

hey please i have a question on bloc engine its marked the bore cylinder class , for example "abac" can i use piston classe "B 71.98" if the cylinder classe "a 72.00" is worn but still in the limit of classe b lets say 72.02" ? the mix is possible ? cause the workshop says that if classe "a" exced the limit , rebore the cylinder 0.1 and use oversize 0.1 piston Cylinder "A" 72,00-72.01 /// Piston "A" 71,965-71,97 Cylinder "B" 72.01-72.02 /// Piston "B" 71,97-71,98 Cylinder "C" 72.02-72.03 /// Piston "C" 71,98-71,99 over size cylinder "A" 72.10-72.11 /// over size piston "A" 72,065-72,07 over size cylinder "B" 72.11-72.12 /// over size piston "B" 72,07-72,08 over size cylinder "C" 72.12-72.13 /// over size piston "C" 72,08-72,09

[@eventhorizonlemonscar6139]

The terminology used here is something I am not familiar with and do not feel that I can provide you the advice you're looking for. If the workshop specializes in engine machine work, then I would defer to their knowledge and recommendation.

[@psavel274]

Not entirely sure if itll fit but I know that VW sells an OEM windage tray with the gasket that fits a 16v no problem. I'd do a search but I'm willing to bet they exist and the 16v one may fit with little or no mods.

[@eventhorizonlemonscar6139]

Thank you for your comment and Yes, there are windage tray options available to purchase. Yet, to stay within the lemons budget and since I'm cheap, have a welder and sheet metal laying around, I fabricated one. Welded it into the spare oil pan and stuck it on the engine. I thought about extending the front section of the oil pan out to have more capacity but I didn't have enough metal and I wasn't sure if I'd run into clearance problems with something else on the car later.

[@psavel274]

@@eventhorizonlemonscar6139 Extending the pan isn't really necessary on these motors. You can run it a little over full as I have done with no adverse effects. I'd install a catch can just for peace of mind, and if you really want to make an improvement in the stock oiling system, get yourself a remote oil cooler and mount it in the rad support/ grille area. You can scrounge one from something that has one stock, as there are plenty of cars that come with an OEM one. You don't have to go all out with a Setrab one in the spirit of Lemons I agree with keeping it as cheap as possible.

[@ThaboSekamo]

Which size install mini berings

[@shoestatus]

who sells rebuild kit for these engines ?

[@eventhorizonlemonscar6139]

I'm not sure of a complete kit with gaskets, pistons, bearings, etc. I would go to rockauto.com and piece together what you need. They should have a gasket set, then pick your bearings. They may also have pistons, or you may have to go to another supplier for that. I just redid the bottom end with ARP rod bolts for more piece of mind and took the time to install new pistons. For pistons, someone much smarter than I, told me about these www.ebay.com/itm/371367003251 They fit, or of higher compression, and are economically priced. They've survived two races so far.

[@siphoernest2278]

43 f.p ?