Had a flat spot at around 4k revs for a couple of weeks now on my '92 G40, noticed today that my coolant level had gone down slightly so I looked at things a bit closer and found that there is a very tiny leak of water from a corner of the headgasket so next weekend my brother (qualified mechanic!) is going to replace the head gasket for me, he's given me a list of parts which we need for the job and I am struggling to find them all on t'interweb. I have checked GSF, Euro Car Parts and the like but can't seem to find all the bits needed. Can anyone advise me where to look? Needs to be ordered on t'internet as I will be working all week and won't get time to ring around etc

Apparently the following is needed:

Head Gasket

Cambelt

Exhaust manifold to downpipe-gasket

Manifold to head-gasket

antifreeze

oil and filter-Already Got

Rocker cover-gasket

Oh and he was unsure if the headbolts need to be replaced? If yes then where do I get these from?

Appreciate any help guys, thank you in advance

Yep make sure you get new head bolts because they are angle tightened at the end. If you are not using the main dealer for parts then you will have to get an Elring headgasket for a mk4 polo 1.4/1.6 8v and a set of standard mk3 polo head bolts from GSF. They will be able to source the other bits for you to, except the rocker gasket which is VW only stocked. Head to exhaust manifold gasket is ok from GSF, but the manifold to downpipe gasket is VW only for the G40.

so basically VW for the lot then to keep things simple? I wont have time to ring about this week and need the car fixed on saturday! thanks for that matey

you may all laugh but I'm not mechanically minded....how many head bolts do I need to get?

you may all laugh but I'm not mechanically minded....how many head bolts do I need to get?

10 iirc

you may all laugh but I'm not mechanically minded....how many head bolts do I need to get?

10 iirc

the headbolts on a g40 are very slightly longer although it shouldnt make much difference. those parts you have listed are not very expensive from vag anyway. you could ring them ask them to get them in and then pick them up??

Get a new water pump whilst you are at it too, they seize over time and can cause your cam belt to snap. If I was doing all that I would do the water pump too, you have to take it off anyway.

Get a new water pump whilst you are at it too, they seize over time and can cause your cam belt to snap. If I was doing all that I would do the water pump too, you have to take it off anyway.

only about 30 quid from vag too. well remembered there sam.

you'll obviously need coolant too

Which is in his list...

oops..

budget for 4bottom pulley bolts as they usually mash with a cam belt change

water pump is going on the list aswell then, thanks for that

Edited 17 February, 200818 yr by 123stevevw

water pump is £40 and you have to give them your old one too i think....

I bought a head gasket set when i did mine, came with everything apart from headbolts and a timing belt. I think i spent about £70 or £80 for bits when we did mine back in the summer, minus the waterpump.

Hope this helps to price things up,

Martin

i paid 28 quid for a waterpump from VAG

did you have to exchange it?

did you have to exchange it?

i cant remember i think so...

when you exchange do you have to give your old one to them first or will they wait until you've done the repair and then trust you to take it in?

when you exchange do you have to give your old one to them first or will they wait until you've done the repair and then trust you to take it in?

afterwards. you sometimes put a deposit down which you get back when you bring it back.

What I have ordered so far;

Head to manifold gasket

oil

oil filter

head bolts

inlet manifold

anti freeze

waterpump (GSF!!)

Total so far= £60.61

Apparently I still need;

Head gasket

Rocker cover gasket

Manifold to downpipe gasket

bottom pulley bolts

Some rough and some medium course sandpaper

WD40

What grit paper do I get?

Sorry to keep askin what you guys may consider silly questions but I haven't gotta clue with mechanical stuff (some basic things maybe!). If you think of any other bits I may need then please say cuz my brother is doin this for me on Saturday and if something goes wrong that we can't get parts or whatever for on Saturday then I'm f*cked and can't get to work next week!!!!!

Edited 17 February, 200818 yr by 123stevevw

exhaust manifold nuts are woth replacing as the chances are, they're at least 14+ years old and can get rotten etc.

Bit of useful advice, i'd spray the 5 manifold nuts with wd40 once or twice a day up until you take the head off, then hopefully the nuts will be lubed up enough to unscrew.

Martin

is the PSD metal gasket not any good then? R the VAG ones metal inserted?

Edited 18 February, 200818 yr by rixy

is the PSD metal gasket not any good then? R the VAG ones metal inserted?

11133B from GSF is what you want for a metal HG (has wide enough bores for a 2mm overbore - i.e. 1341cc conversions). I think there are a couple of other slightly thicker alternatives too if you're still 1272cc, can't remember those numbers off the top of my head though - one is the Golf ABD HG I think.

Oh - and buy VAG exhaust manifold gaskets, the Mk3 Polo ones from GSF are poo.

that part code comes up as a gasket for 1.4 and 1.6 engines from mk3 golfs and mk4 polos.

that part code comes up as a gasket for 1.4 and 1.6 engines from mk3 golfs and mk4 polos.

what a fuss ring vw say i want a head gasket for a g40 engine code py. 12 quid later. its yours sorted.

that part code comes up as a gasket for 1.4 and 1.6 engines from mk3 golfs and mk4 polos.

Ja. Been using one for a few years now - though PSD originally put my engine together with a stock G40 gasket I supplied, which wasn't really suitable for an overbored block.

The Golf one for the 1.4 ABD engine is good for the 1272cc boys, but doesn't give such an increase in CR if memory serves - not sure if the GSF one (11132) is metal or not though. Some of the Italian OEM part suppliers definately do metal ones for the ABD.