tech procedures, warnings on 16V rocco (very long, sorry)

[Chris Coracini <Coracin@usdl.com>]

over the holidays i spent 6 days replacing a BUNCH of stuff on my 16V
scirocco:

all new motor mounts (TT 16V rocco motor mount package....  AWESOME!!!)
new injector seals (see warning below...)
two new injectors... (ditto)
new oil pan gasket
new crank seal
new input shaft and clutch pushrod seal
new flange seals
new shiftrod seal
new shifter bushings
new heater valve
new thermostat
re-re-engineered home-brew short shift (barely more than 3 inches from
3rd to 4th now)
new clutch disk
installed lightened flywheel...  (WOOHOO!!!)
a few new hoses
replaced speedometer cable end gear with the correct one for 2H
transmission
mobil 1 w/ lubro moly anti-friction treatment
redline MT-90 (cured 2nd gear crunch, REDLINE ROCKS!!!)



INJECTOR O-RINGS (warning):

these $10 parts cost me a total of a days work and $115 for two new
injectors and four new lower inserts...  here's what happened..

the injectors are held in place only by the O-rings, right?  right.  to
remove the injectors "simply pull on them, and they will come out".  (i
like that they inserted the word "simply" in there).  well, one problem
was that my O-rings were so old that they had turned to ceramic.  they
were literally as hard as rocks.  another problem (only for 16V's) is
that you CAN NOT get a grip on these things, because they are inserted
in the little itty bitty space between the intake plenums, so it is
impossible to get a good grip to get them out.  i tried (even though it
said not to) to pull on the stiff tube part of the fuel line, i pulled
with all the strength i had, they didn't budge a millimeter..  they were
a little loose, but they just wouldn't come out.  so i had to break out
the good ol' wonder bar and pry them out.  but again, you can't get a
good grip on them because they are so buried...  but i pried.  and pried
harder.  i pried so hard the engine was rocking...  then.....  (snap).
what was that?  why is the injector so loose?  why won't they STILL come
out even though they are so loose?  i was pissed because i knew i broke
something, what.... i wasn't sure yet.  so i gave one last pry and out
it popped...  one very bent injector (ruined) with two ROCK HARD (i mean
ROCK hard...) O-rings.  %$#^$!!!  well, i had to get them out right?  so
i tried the next one (snap), and the next (snap) and the next (snap).  i
managed to get the last two out without bending them...  and the snap?
that was the lower inserts breaking (they're plastic, and very brittle
when old....)  so, i had to take the entire intake manifold off to get
the little craps that fell into the intake port (and luckily not into
the engine....)  THEN i had to take out the brass inserts (PAIN!!!) to
put new lower inserts in there, and putting those brass ones back is
ANOTHER pain i will hopefully NEVER have to do again...  got two new
injectors (50 bucks a pop...) and put new O-rings on the old ones...
put them all back in.  took me the about 8 hours labor time...  so
here's the warning.  you must be VERY careful to pry PERFECTLY straight
out, which in nearly impossible to do anyway.  my advice would be to
change these things BEFORE they petrify and permanently lodge themselves
(and their vacuum leaks) in the inserts, or you will be looking at a
heap of work that will probably be best left to a dealer.  that way, in
case they break something you won't have to pay for it.


4 NEW ENGINE MOUNTS:

i ordered the 4 mount package specifically for the 16V scirocco from TT.
 $90!!  not bad at all.  this has the stiffer front and passenger
mounts, along with the driver's side and rear mounts.  the passenger
side has an offset bushing specifically for the 16V scirocco.  the front
and rear are simple enough to change.  to get to the passenger side, i
installed the front and rear, then removed the bolts from the pass. side
and driver's side mounts, put a jack under the oil pan on the outer edge
next to the wheel.  then disconnected all hoses from the back of the
throttle body and manifold.  then lifted the jack so the pass. mount is
up about 3 or 4 inches.  the bracket comes off pretty easily from behind
the belts.  to get the driver's side, i removed the inner wheel lining,
then took off the two bolts that hold it to the tranny.  (i used the
"access" holes i drilled into the fender wall previously to get to
them).  these mounts must be pressed in with a machine press.  couldn't
do it myself so that's the only outside labor monies i had to spend: 56
bucks, unfortunately, because i took it to VW.  this is interesting,
though:  the pass. side mount was installed UPSIDE DOWN previously (with
the bolt closer to the top of the mount!!).  what moron did this?  no
wonder it felt like a vibrating bed.  anyway, i had them pressed in the
RIGHT way, installed them, and WOW...  it feels like a new car!!  very
quiet.  when i was idling at a stop light, i had to look at the tach to
see if my car was running!!  no lie!!  and engine rocking is
dramatically reduced...  the mount kit is HIGHLY recommended!!  and it
fit PERFECTLY, no straining!!  just make sure to align the engine
properly....  


LIGHTENED FLYWHEEL:

this rocks.  it's not a BIG difference, but it does feel "zippier",
especially in 1st and 2nd.  this thing is a stop light rocket with the
3.94 and the lightened flywheel!  what i have is your basic 210mm
flywheel with all the extra weight past the ring gear machined off.

CRANKCASE BREATHER HOSE:

not the one connected to the intake boot, the little short one right on
the block...  i don't know how many of you guys check this when looking
for vacuum leaks, but i never did.  i never even knew it existed until i
had to take the intake manifold off.  it's hidden beneath the intake
manifold on the block (towards the front of the car.)  mine was split,
and not only was is a nice sized vacuum leak, but it was also another
nice oil leak too...  it's only about 3 inches long by 1 1/2 inch
around, a piece of crap nothing, but VW had to ORDER the bitch...  i
just got a piece of a radiator hose for some car at pep boys that
matched the diameter and just cut off the right length.  this hose is
sure to fail because its insides are soaked in oil all the time, and oil
makes the rubber soft....  

all the rest of the list i'm sure you guys know how to do, so i won't
bother (this is long winded enough anyway).  BUT, if anyone needs any
info on how i replaced/fixed anything on that list, i'll be glad to help
you out.  needless to say, my scirocco is a NEW CAR!!  it's so amazingly
quiet it's scary, no vibrations, VERY fast, immediate throttle response
thanks to zero vacuum leaks and the lightened flywheel.  looks like i'm
keeping her for a long time to come...

chris
86 16V scirocco

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