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My OHC has been begging for some serious attention since a while now and I plan to get some good check up done. Please advise what all should I include in my checklist.

I will post a list of existing problems, work done recently, and things that I plan to get done.

Car: 1998 Type 1 - OHC 1.5Exi

Odo: 1,25,xxx kms

Problems:
EML light comes on after a while. The speedo was the first thing that failed when this happened for the first time. Require a full scan to check the O2 sensor and the VSS (Vehicle Speed Sensor) and replace.

Shudders/jerks mostly at RPMs till 2500. Got injectors cleaned but did not help.

Steering has become considerably hard. Tyres are Michelin XM1 in 185/70/R13 in decent condition.

Clutch seems to be at the end of it's life.

Replacements and Checks to be done:

1. Replace sensor (depending on which one)
2. Replace clutch cable and check full clutch system
3. Replace Timing belt and bearings and check water pump
4. Replace hand brake cable
5. Replace hood release cable
6. Replace Speedo cable (if required or is it?)
7. Replace brake pads and brake shoes. Check full braking system. Disk facing etc
8. Check all hoses
9. Replace fuel filter check fuel lines etc
10. Replace spark plugs and check distributor + wires
11. Check valve clearance
12. Check compression
13. Full engine tuning
14. Check Steering system (Can I just get it serviced/overhauled?)
15. Check door alignments
16. Might replace the HL assemblies
17. ?? ?? ??

The full front suspension was changed about 10k kms back so have not included that in the list. Rear suspension will be checked.

Please give your inputs since I require a thorough check and do not want to miss out on anything important. Can someone also give a rough idea as to how much will all this cost.

Sorry about the long post! :)

How about a replacing the car itself. Its an old horse now!

I had a similar steering problem in my type 2 OHC. Needed to go to a turner and get the steering assembly re-turned.

Even check the steering oil reservoir, mine had developed leaks as well. You should rather check all the reservoirs.

Spark plug replacement should take care of the jerks.

May also need to reset the ECU.

Clutch and wire will need to be replaced for sure.

Check all windows and windscreen rubber linings. They deteriorate after a lac kms and will come loose in high speeds.


Replace all fan belts and hose pipes.

Get a fuel tank clean up. When was your fuel pump changed last if ever?

Carbon clean not recommended.

Get all power window assemblies check, especially the back ones if they are hardly used.

And ofcourse muffler check.

Will keep posted if i think of more.

P.S. After a good maintenance regime, your old horse will easily run (Gallop!) for another lac kms. OHC's are the best!

Oh come on Abhik :) The old Horse still has a LOT left in it.

Is this the same as a steering over haul? Costs involved?

Added to the list. Fuel pump was never changed. I don't think it requires a change unless it goes bust!

Not at all, have suffered earlier because of it.

Excellent point, added.

Least of my worries since I have a SS end can. :D

I bet it will, thanks for the valuable inputs.

Pretty sad that no one else has anything to say?!? Come on guys.. I'm going spares shopping tomorrow so I need to know.

Yep, its the same thing. A private guy would do it for around 5000bucks. Company costs would be atleast double of that.

Ankit, you might want to breeze through this thread too. Good luck with refurb'ing the OHC.

Thanks GTO, excellent thread. Just what I was looking for!