New Parts, Autotech 13lb flywheel, new clutch and timing chain kit:
The new head gasket/spacer set up will drop compression from 10:1 to 8.5:1. The gasket is comprised of a two piece mk4 metal gasket that is split and then sandwiches the stainless steel spacer. You want to spray the two gaskets (not the spacer with the permatex high temp copper gasket stuff.
New timing chains installed. The head is bolted down using ARP fasteners. Torquing order is same as stock (basically just diagonally from the center out) but the stronger studs can with stand a ton more torque. We stepped it up from 23-49-65-80 ft lbs.
While doing putting the chain covers back on I ran into an issue when installing the upper chain tension. My motor is out of a 96 Jetta, so I have the plastic valve cover and the dual timing chain. This being the first time Ive done the chains on the car, I ordered the new style chain kit-recommended for better durability and ideal for the dual chain setup (also cheaper). The only thing that wasnt back wards compatible with the new timing chain kit was the upper timing chain tensioner bolt. Pictured here is the full chain kit, the tensioner is the large brass bolt in the middle.
The new style upper chain tensioner doesn't thread all the way into the early style upper cover. The problem lies in that the new style cover is threaded all the way through, while the old style (the one i have) isnt threaded all the way. Apparently 92 distributors are some of the only cars to get the "old style" covers - which is what I have to make the new '96 motor work with me obd1 distributor setup.
Not being able to find a 22m x 1.5 Tap locally on the Saturday of memorial day weekend, I oped to port out the back end to get the new style tensioner bolt to thread in all the way. Vortex recommends forcing the new bolt in a 1/4 turn at a time using "lots of oil". I wasnt comfortable with this so I went with the Dremel and never looked back, I only removed (max) a few cubic mills of Al from the back side of the case.
Next up, the valve cover, lightweight flywheel and the clutch assembly.
Modified by corrado-correr at 5:42 PM 5-28-2008