ENGINE ARRIVAL

As you can see, the engine and tranny arrived in a highly corroded state. This was fairly surprising given the low mileage of only 8k

The engine and tranny were purchased from a wrecking yard in Virginia and then shipped to Dan's work on a pallet.

INTAKE MANIFOLD

Here you can see the intake manifold, AWP head, and exhaust manifold.

The intake ports come in two sizes amongst 1.8T engines. Shocky has the smaller intake port size, common to all later model 1.8Ts in the US.

EXHAUST MANIFOLD

The exhaust manifolds are the same for all 1.8T engines in terms of port size. Since the AWP exhaust manifold is fairly restrictive and the KO3/KO3s turbo is fairly small, Shocky now sports an ATP manifold with a GT30R instead.

CYLINDER HEAD

The AWP cylinder head in all its corroded glory......

...and the cam cover....

...and the cam cover's cover.... Shocky's cam cover was so beautiful after cleaning it up that I chose not to use this.

INTAKE PORTS

Here you can see the intake ports on the cylinder head.

EXHAUST PORTS

...and the exhaust ports....

VALVES

5 valves per cylinder, baby!......Two intake, three exhaust...... Even though VW has decided to go back to four valves per cylinder....I still love all 20 of my valves.....

ENGINE BLOCK

Shocky's block was very rusty for having only 8k miles on it. In the picture to the left you can see the bathroom scale that Dan and I used to weigh the block. The AWP block weighs roughly 140 lbs. (+/- a few pounds due to the inaccuracy of a bathroom scale).

PREP FOR PAINTING

Dan and I spent quite a bit of time cleaning out all the nooks and crannies that had rust festering inside. Then we masked off all of the openings in preperation for painting the block.

For the paint, we used engine enamel spray paint in semi-gloss black (or maybe it was low gloss...can't recall).