VW 5-Valve Cylinder Head Resurfacing

[homenucleonic666]

great vid and very interesting process, thanks for sharing (I got a V70 T5 so I appreciate !)

[GruppeB]

what's the shiny grey stuff on the areas in-between where the valves go?

[fiatnutz]

@GruppeB - Its a dry graphite spray we usae to coat the combustion chamber when we do a valve job.

[jcotteri]

Great video mate. Thanks!

[ringlol]

I wish you lived in my neighbourhood so you could resurface my block and head. Have you even done a Inline-5 ?

[fiatnutz]

@ringlol - I'm currently doing a performance version of a Volvo S60R engine.

[1971ojoalparche1971]

In general terms, is it a good idea to resurface the head if all one wants is more power? I know it's done quite a lot, but I'm under the impression this process should only be done to level the head and not to increase power. I'm thinking the original design of the block is what it is for a reason, and it shouldn't be messed with if it can be avoided. Is this correct? Thanks.

[danthaman101]

I can watch this type of work all day!

[chr1s88blue]

did you put a coating on the head b4 you machined it ? i noticed after you resurfaced it the chamber or part were the valves sit was darker.

[fiatnutz]

@chr1s88blue - That;s because I sprayed the combustion chamber with a dry graphite film.

[Blade4613]

so, 2 valves are for aspiration 2 to get the exhaust gas out... what's the use for the fifth?

[fiatnutz]

@Blade4613 - two exhaust valves and three intake.

[Blade4613]

@fiatnutz oh ok thanks! another question, does this 5 valves per cilinder in a 4 cilinder engine perform better than 4 valves per cilinder in a 4 cilinder engine?

[vwgtirancher]

@fiatnutz its 3 exhaust and 2 intake it helps the turbo more that way

[fiatnutz]

@vwgtirancher - There are 3 intake valves and 2 exhaust valves - take a look at the ports on the head.

[vwgtirancher]

@fiatnutz ok i see that now. i was confused because to me it would make more sense to have a 3rd exhaust valve to get the burnt gas out faster so more could come in. i thought that adding the turbo would already improve the intake and an extra exhaust would further improve the effects of the turbo a lot more than the extra intake valve would because a motor is only as powerful as it is efficient

[douro20]

@vwgtirancher

I've never heard of a five-valve head with three exhaust valves. The general consensus is that all 5-valve heads have three intake valves.

[JGMagoo]

@Blade4613 Most likely 3 for intake (to make it breathe easier) and 2 for exhaust. The greater the total valve area, the easier an engine will breathe. This engine, as you can see, has about the maximum possible valve area, which should make it very efficient.

[Blade4613]

@JGMagoo yes, but why not make a 6th valve? so the gas will flow out more quickly

[fiatnutz]

@Blade4613 - Maserati did this on one of their engines, but went back to 4-valves - less friction.

[Blade4613]

@fiatnutz oh ye? well somethimes then bigger is not better and too many things it's not better

[JGMagoo]

@JGMagoo Look carefully at the combustion chamber shown. If you can find room for a 6th valve, tell VW how to do it. (LOL) Actually, exhaust is not quite as critical, as the exhaust is forced out of the cylinder by the piston on the exhaust stroke...whereas intake relies (usually) on vacuum and atmospheric pressure in order to flow into the cylinder.

[donwonjon420]

wow i didnt know vw had a 5 valve head, I though yamaha motorcycles were the only one to use 5 valves per cylinder. That really cool

[jrgm3]

I have a Range Rover with a VM diesel engine that I'm rebuilding because a broken injector sleeve (damaged a piston and the turbo).

I think the heads (one per cylinder) must be resurfaced, but the workshop manual says that must not be done because the heads are nickel plated.

The heads are a bit expensive (400 Euros each), and I'm trying to avoid buying new ones...

What you think? Resurface? Or not?

Thanks in advance!

Cheers from Portugal

[DIOSpeedDemon]

How much can you take off to true the deck surface and not interfere with the valves or compressin? THank you great video, and do you have to do this to both heads if you have two heads? thanks RH DSD

[fiatnutz]

@DIOSpeedDemon - VW sez that you cannot remove more than .004", but we take as much as .015" w/o any probelms. Compression increase is about .1.

[dnl5649]

holy s$%# 5 valves!!!

i was about to say 5 valves!!! maybe 6 valves if its a 3 cylinder, i didn't know you meant 5 per cylinder!!!!!!!!!! how much h.p.?

[DYNAMIZER]

@dnl5649 it's about 150 hp

[odzadze123]

@dnl5649

1.8 20V

150Hp or 180Hp in vw

in Audi's this engine (slightly modified) develop 225Hp or 250Hp in Audi TT

for British market.

[samanthanjosh]

if compression gets higher than recommended, wont that blow out seals?

[3star2nr]

Hi how are you doing I was wondering is it possible to resurface a head on a conventional end mill. Like if you just have the cutting tool.

What would be the disadvantage to doing it on a end mill?

[pastorboy0]

@3star2nr Yeah, use a fly cutter. Be very careful, and cut as little as possible. It would be more precise if you took it to a machine shop, but yes, it could be done if you have a modicum of machining skills. Also, make sure that you are completely square (obviously) and also use an extremely sharp tool, otherwise you will probably ruin the head.

[jgizzy]

It's acutally 1.8t (T), not I (i). Just thought I'd point that out, love your vids keep em up I watch all of them.

[MK4bora28l]

shouldn't this also increase the compression ratio?

[m99tehfish]

It does, depending on how much you take off.

[fiatnutz]

Rule of thumb is for every .010" you remove, the compressioin increases .1 c/r point.

[Rennpanzer]

@fiatnutz How often do you find it necessary to resurface the top of the block as well? (JH motor)

[BLOODYCLQ]

@fiatnutz whould you be able to tell me what cause this damage on the heads?, and is there anyway to understand the crack head by myself without xray it. cheers.

[3star2nr]

yes it does it also changes the timing of the engine. When you resurface the head and deck the block you should get adjustable cam gears to dial back in the cams.

Note however, that engines are designed with tolerances so the manufacturer allows you to cut a few thousands off the head and block without affecting the engine that much

[Hollrobb]

@MK4bora28l Also my question.

[ding7988]

i have build several of these engines , people seem to be scared of the work involved or the shop bill? i have a 98 in my garage right now with 81k miles (broken belt) $600 labor (to build head)and gaskets runs like new .... This was a 1 owner car with a new turbo and new tires for $1000 off craigslist..now its worth 4-6k.....

[mikenw255]

I understand that a broken timing belt = bent valves, but why is the head warped too? For a while I was thinking of getting a New Bug but this makes me pause.

[Whipit8rapture]

From every one ive heard they burn a lot of oil, perhaps low tolerance levels in the factory are the reason.

[donkeytits1]

This is all pretty hear say, i don't know why they would bother designing an engine with 5 valves, which is a performance design feature not a nessesity and then make it with massive tollarances or with poor ring materials. remember these are presige cars too.

Advances in manufacturing technology have allowed the ecconomical use of smaller tollarences in modern cars and very few have problems such as excessive oil consumption.

[Whipit8rapture]

right ok....

[naturalyshocked]

they answer is ver simple, it's the same as why people invented multivalve engines.

answer: the air has less effort to get in and better fuel vaporization.

the midle of the 3 intake valves has a different timing.

[donkeytits1]

Timing belts can break on any car esspecially the belt is not inspected and replaced at the correct intervals or shit like oil gets on it.

I would not be put off buying any car due to one isolated instance of a failure, esspecially somthing like a timing belt which is a bit of a weak point in any engine (that uses a timing belt, pretty much every modern engine).

[ding7988]

oil leak will kill a belt faster than anything..once the oil gets on a belt it's junk replace it and the oil leak..

[marek0086]

id say more newer cars would be running an internal chain instead of belt.

Not much difference in efficiency... but much longer life.

[3star2nr]

Well for high performance high reving engines there is a very big advantage to running chain over belt. For instance the mitsubishi 6G72 engine is belt driven. When you raise the revs to like 10,500rpms the bolt holding the idler pulley comes lose causing the belt to lose tension and makes the engine jump timing.

The belt itself can also slip and jump timing.

IMHO the chain drive once the cams are properly dialed in is the safer setup. The only disadvantage is weight, and also lubrication.

[naturalyshocked]

vw recommends 60.000km, but 90.000 can be done.

[naturalyshocked]

you can do 90.000km/h with a belt, but 60k km is recommended.

it's a nice engine

[workensmart]

this is some cool stuff. I have a GM 3800 serise 2 supercharged. I have a set of heads I want to get larger valves put in. how much would this cost if I send the heads to you?. Also would you recomend milling the heads since they are from a different engine?

[MrGuvEuroman]

Is it smoother the finish the better John? Or can they be too smooth? ^_^

[timsamuels1971]

Change that time belt, if you dont your looking at 850.00 in parts and laybor if your lucky. head has vary small valves that bend easy.

[headrebuilding]

fanci equipment is just to impress and to raise your prices, I can do the same head half your price.

[fiatnutz]

If you say so...

[scottklarr]

headrebuilding: I suppose you think proper grammar and spelling are things only used to impress too, right?

Any redneck and throw together an engine in their back yard; That doesn't mean its going to be as durable as one built to perfect spec using "fanci" tools.

[headrebuilding]

Any redneck "and" throw together an engine in their back yard

cry baby!

[scottklarr]

Brilliant comeback!

/sarcasm

[jacktheripped]

I had a 151 Iron Duke Pontiac head done at a "low cost" machine shop, I wanted to have the valves larger from 1.50 exaust to 1.6 and the intake from 1.72 to 1.88 Pontiac valves. dude fucked them up so bad by the time the 2nd race shop fixed them i was over $800 into ONE cylinder head, for not much more I could have bought a Super Duty head!!

But now these heads have 1.6 exaust and 1.94 Chevy valves and a port&polish job, polished combustion chamber and ARP rocker arm and head studs :)

[libertypatrol]

What????

not fancy equipment

technology equipment so that your car can run properly.

don't you read the stub when you get your car fixed.

every garage charges almost the same in labour.

[Rennpanzer]

@headrebuilding Just the same, I think I'd take my head to the guy with the "fanci" equipment. I don't know of too many auto enthusiasts who'd be inclined to have their machine work done by someone who doesn't seem to be able to spell.

[Maximusfool]

@headrebuilding And what machinery would you use ?? I think you are just another Mr KNow it all

[marshkid1]

You Da Man.

[ronieboy44]

Cool video..I have never seen a head like that before..

[mikeromeo2]

Mr Edwards, I am curious if you double check with a feeler gauge and straightedge after the resurfacing?

[fiatnutz]

Not on every head because I check heads in the machine with the dial indicator. What I do find, occasionally are twisted head and I have to shim the head at diagonal ends to split the difference, but when the heads come off, they are straight.

[enginemasterbuilder]

NEVERMIND I HAVE MY ANSWER lol.

[enginemasterbuilder]

JOHN I FORGET HOW TO CALCULATE RA? EMAIL ME IF YOU CAN Its peter.

[kingfiisher]

profileometer???????????

What's wrong with the one god gave you?

It's on the end of your finger it's called a finger nail.

[fiatnutz]

Can you tell me how you calibrate your finger nail???????? And, can you tell the difference between 20 Ra and 21 Ra? My standards are a lot higher than what you can point, feel, or scratch with your finger nail. The main reason for these videos is to educate those who are not familiar with high precision machine work and practices. I don't know that god had your finger nail in mind for this inspection process in the original human life form design. JE...

[Silverbullet38]

Very interesting. I had never seen a 20 valve head.