mrj
Posted a lot
Posts: 1,662
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Feb 28, 2010 19:53:10 GMT
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on sunday, when everyone goes to church here, i usually escape into the workshop... time to dismantle the engine : i couldn't believe it, but i was able, to remove the exhaust almost in one piece.... that cast header on the top left in the pic must be replaced, though. I can't see to get all the bolts out, as you can't even guess what size they are . Not bad actually for a +20 year old engine ... also the pipe between header and cat must be replaced, that might be one reason for not having the full performance, as the hole is in the same location as the lambda sensor .... i cleaned the engine a little bit with brake cleaner, as i don't want to drop off an oily engine at the other workshop... i could remove all the studs from the exhaust, i don't have to drill them out.... i also tried to open the nuts for the headbolts, they move ... which is success, as on some engine the headbolts brake,and that is a big problem, as you mostly need a new crankcase.... still i can't see the reason for the oil leakage; though the flywheel shows some oil marks and the pushrod tubes are oily.... i could have taken the heads off today, but i'll be doing that at my mates workshop this week.... so far i am happy, looks good, though we will see what happens when the heads are off ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Feb 28, 2010 20:00:45 GMT
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good luck with the head removal . i found a corroded stud in mine ,luckily we got it out, or the case would have been scrap. i had three snapped manifold studs as well which had to be drilled and tapped ,so hopefully your having none is a good omen..
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66 Beetle
63 thunderbird
97 mx5
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mrj
Posted a lot
Posts: 1,662
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Feb 28, 2010 20:54:04 GMT
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good luck with the head removal . I found a corroded stud in mine ,luckily we got it out, or the case would have been scrap. I had three snapped manifold studs as well which had to be drilled and tapped ,so hopefully your having none is a good omen.. i think half of the manifold nuts were missing or lose, so i was already lucky ... i have another case here, unfortunately my Passat trunklid fell onto it and 50% of the rear screen is in the case now Actually, i have no problem with the head gaskets, but i want to have that engine 100% reliable, as it will be my summer daily and my tow car. As the need to tow car trailers will increase this year , it must be running faultless. I am taking it out now and don't want to repeat it each year. If i hadn't to pay the house, if i didn't lose my job and if my wife wouldn't be pregnant, i'd buy a brand new engine .... though the combination of all three above gives me the chance, to spend more time on the cars and learn some more stuff on these engines... if i am lucky, all the parts and labour will be below 1K € , a new engine from VW would be 2800 €, so there is some money to save .... i was also playing with an engine conversion, there are some nice ones out there (Subaru, VW 2,0l inline etc.) , but i think the soul of that van lives with the waterboxed engine.... and if these engines are new/proper rebuild, they will last a while ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Love the knew pop top. I have a Turret top , was it quite easy to do ?any advice would be cool as I would love my Reimo to be a 4 birth!
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mrj
Posted a lot
Posts: 1,662
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Love the knew pop top. I have a Turret top , was it quite easy to do ?any advice would be cool as I would love my Reimo to be a 4 birth! it was pretty easy to fit, as the roof from the van already had a hole.... if you cut a hole, try to look at a Westfalia van and measure the distance from the rain gutter to the hole ; everything else is straight forward. Unfortunately the previous owner fitted that huge roof and made the hole too wide for the roof, so i had to cheat a little bit . And this roof isn't a Westfalia at all, its just a sticker from ebay... it looks very similar to a Westafalia though and that combined with the stickers was ok for the german TÜV . I want to change the roof, as i am not happy with it at all; maybe i will replace the roof skin or put on another roof.... but not this year ,.... a friend of me is regularly scrapping those and sells the parts, when the right roof comes, the grinder is on....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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well, no pics here yet of the engine in parts, but close your eyes and imagine burnt valve seats, a total worn out valve train .... the heads have no cracks, but the condition of the rockers and valves makes me guess the real mileage of the engine.... i was considering new heads, but i guess the crankshaft/camshaft will be in similar condition, so i am already chasing a secondhand engine .... so, the shopping list would be : 2 heads = 800 € gasket kit = 300 € couple of exhaust parts = 150 € pistons and liners = 600 € and add labour to that, i could happily buy a rebuilt engine from VW .... a friend of me is breaking a Ex-Police Type 25 with that engine at the moment, so i might be off to Frankfurt next week and pick that up.... rumours are, that the police had different ECUs and more BHP, i'll have a look at that ECU then ;D
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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progress....
Just gave Dave your new Passat manual.
He will bring it to you later.
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mrj
Posted a lot
Posts: 1,662
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Mar 21, 2010 11:10:56 GMT
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i found some rust .... (it wouldn't be mine without ;D ) on all 4 corners ... also bought a new gearbox lift, which of course comes from china, weighs a ton, but was cheap.... there are a couple of clutches coming in the next months, so i can well use it, and it allows me to put a tub on it, so it's handy for changing the oil etc ... I'll be picking up the "new" engine on tuesday, so with a little luck it'll be running before easter.... i'll go for that police van engine, as my mate is breaking that van and offered me the engine for 350 Euros, without looking at it closely. Now he found out that the case is gold and it still has a sticker on it, that it was a factory rebuilt engine. He still wants 350 for that, so that's fair and i am lucky ... he also takes my old engine back and will refund some euros on that, that is a great deal .... i also bought a polishing machine (cheap one from ebay) which really isn't bad at all . I tried it on the Jetta bonnet, the surface of the bonnet was like sanding paper : and after : in the first attempt i didn't have the proper polish, but changed that today and i am really happy, especially that there are no clouds or swirls.... so the Bus will also get some detailling as soon as it is running again.... since then, i have a couple of matt red cars in the fleet ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Mar 21, 2010 11:28:59 GMT
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Ouh for that rust, but no doubt you will fix it soon.
Polisher looks a bargain too.
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mrj
Posted a lot
Posts: 1,662
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Mar 21, 2010 11:57:00 GMT
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Ouh for that rust, but no doubt you will fix it soon. Polisher looks a bargain too. the rust isn't a big problem, considering the van is getting 22 this year.... i already ordered the panels for the front, for the rear i am making my own .... the polisher actually was a bargain, it was 79 Euros including a lot of different pads and polishing stuff .... if you buy a "proper" one for professionals , you'll start with 400 Euros.... as i won't be using the machine each day, i can really live with it being cheaper .....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Mar 22, 2010 20:59:28 GMT
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step by step was todays motto : started with the passenger side step : trialfitting of the cut-down panel .... then it was time to remove the rust ... rust was cut out ... some welding primer applied ... now some people don't like gasless welders, i do .... though it is a bit messy ... cleaned up... i'll be finishing the other side this week, tomorrow i will be going to Frankfurt and pick up the new engine ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Apr 17, 2010 22:10:03 GMT
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we had fantastic weather today, so i went into the workshop first of all, this is the new engine : actually it is a rebuilt engine taken from a Polizei transporter, looks very clean .... i replaced a couple of gaskets, checked the valve clearance (though it has hydraulic lifters it is advisable to check & adjust the clearance from time to time...) .... i have a transporter specialist next door, and as i wanted to support him (business is running not so well obviously) and buy the necessary parts from him, he wasn't able to order the stuff (or didn't have time whatsoever); this took three weeks and then i went to Volkswagen and ordered the necessary parts and got them the next day. Fair play, i could buy the stuff on his account and got a huge discount, but sometimes it makes you wonder, why you have to force other people to make a profit engine was in pretty fast .... and it is running very smooth and quiet, hopefully i don't have to take it out each year .... i still have problems with the oil buzzer, it starts to flash and buzz at 3000 rpm; the engine can't be the cause, as i had the problem with the old engine, too . Probably i'll put an axe into the dashboard ... i also fitted a shortshift conversion, as reverse, second and fourth gear puts your fist into the stereo, the 5speed boxes don't have the smoothest gearchange anyway. Well, it seems to work, but i don't have a reverse now, it needs some more adjustment .... i also replaced all the rubber couplings for the steering ; not really necessary, but the TÜV man is always happy when he sees new steering parts then i started to look at the drivers side floorpan or what was left of it ... you see the holes, but the floor pan is thin like paper; so i got a replacement : it even came in the same colour ;D I'll be welding that in tomorrow .... i also changed the throttle cable, i bought that two years ago and never got round to replace it. It wasn't necessary, but i like a reliable car and don't want to break down at the end of the world just because of that cable ... i bleeded the clutch and then it was time to finish... tomorrow my wife has some guests (she was having birthday yesterday) , so i hope it is not unpolite to leave the coffee table and go on welding ;D
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Apr 22, 2010 19:23:49 GMT
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in the last couple of days i made a big progress; some pics here : that's the "new" engine in place; had to remove/fit the rear traverse a couple of times, as the exhaust wasn't fitted to the engine and i found out, that it is easier to fit the engine without exhaust, but harder to fit the exhaust with the engine fitted i bought a hydraulic gearbox lifter, that makes life a lot easier.... back to the floor pan : i put the replacement pan on the old one, took a spray and marked the position.... that reminded me of one of Rod Stewarts greatest hits : the first cut is the deepest ... the combination of a tar insulation, lots of dirt and moisture was the reason for the rust; so no more insulation in future, just a thick carpet and no rubber mat anymore... no pic from the finished product, i just welded it in. but for once i put the rubber mat back in; as next week i have the TÜV test, they shouldn't see that it is welded; not that i welded it so bad, but when they see it, they start to poke around, ask if you have welded it properly , and if you give the wrong answer, you might be scrapping away all the sealing and Schutz and have another date... so this time, not welded and everything is fine ... it is funny anyway, even if the car is in 110% condition, you won't pass without an advisory. It's just for statistics, that old cars must have at least an advisory, otherwise they do not fill their quotes . But if you see the TUV report, their statistic says "old cars are dangerous" , and they want to introduce an annual inspection... so, for the advisory, the reverse light is not working... strange, but works... ;D then i gave it a proper clean inside/out and a long testdrive.... no oil leaking, drives fantastic and is very quiet... result ... no, these are not the bavarian mountains, this is 5 kms away from my place.... only a few things left to sort out, i have the usual oil pressure buzzer fault, that will be sorted out and next week is TÜV time....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Apr 23, 2010 13:13:24 GMT
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Great work! : ) I've always wanted one of these... one day!
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dungbug
Posted a lot
'Ooligan!
Posts: 2,852
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Apr 23, 2010 13:56:57 GMT
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What a great thread & display of dedication. Well done fella, lovely bus.
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Past: 13 VW Beetles from 1967 - 1974 Bay Window Campers (1973 & 1974) Mini's (1992 Cooper lookalike & 1984 '25 Anniversary) MK2 Polo Coupe S (1984 & 1986) MK2 Polo Breadvan (1981 & 1984) MK4 Escort (1989) MK2 Granada Based Hearse (seriously) Fiat Uno 60S (1986) Punto 60S (1998) Cinq (1997) 1998 Yamaha YZF600R Thundercat 2003 Ford KA
Current: 2004 Ford Focus (barely alive)
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mrj
Posted a lot
Posts: 1,662
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Apr 25, 2010 19:22:15 GMT
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What a great thread & display of dedication. Well done fella, lovely bus. well, dedication, yes... it's like a beautiful woman, you love them though they kill you.... next chapter : the head gaskets are leaking I told the guy that sold the engine to me , that he should change them and i pay him for that ... he said that the gaskets look very good and are soft, they must have been made quite recently.... tonight, i was fixing the last two possible MOT faults, i found 2 huge drops of antifreeze on each head.... it is amazing, the second time i have to force someone to take money from me and earn money .... stupid world ... anyway, i'll order a gasket set tomorrow and next week i'll be doing that job then ... at least i learn something about it .... still, very annoying....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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dungbug
Posted a lot
'Ooligan!
Posts: 2,852
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Apr 25, 2010 21:57:10 GMT
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That's a pi55er that the head gaskets are gone, better to replace them now than find the problem on your next trip to the UK.
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Past: 13 VW Beetles from 1967 - 1974 Bay Window Campers (1973 & 1974) Mini's (1992 Cooper lookalike & 1984 '25 Anniversary) MK2 Polo Coupe S (1984 & 1986) MK2 Polo Breadvan (1981 & 1984) MK4 Escort (1989) MK2 Granada Based Hearse (seriously) Fiat Uno 60S (1986) Punto 60S (1998) Cinq (1997) 1998 Yamaha YZF600R Thundercat 2003 Ford KA
Current: 2004 Ford Focus (barely alive)
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Sorry to read about your new engine woes...time to get rid of those feeble VW lumps and drop a proper engine in there ;D
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mrj
Posted a lot
Posts: 1,662
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That's a pi55er that the head gaskets are gone, better to replace them now than find the problem on your next trip to the UK. definitivly, i don't want to get a breakdown with a boiling engine on the motorway.... i am really a bit pi55ed off, as i told the seller that he should change the gaskets, it was easier when the engine was out ... anyway, the gasket kit is about 120 Euros and one day work.... Sorry to read about your new engine woes...time to get rid of those feeble VW lumps and drop a proper engine in there ;D yes, the current engine is on parole, if there is more trouble coming up, it's time for an engine conversion. Proper in your words would be a 2,9 V6 which is possible, i'd rather think of a Subaru boxer or the VW inline 4 with 2,0l .... though,the local specialist has a 4,2 Audi V8 engine & box ready to put in a Type 25, that surely is out of my budget
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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dungbug
Posted a lot
'Ooligan!
Posts: 2,852
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4.2 Audi engine! That would be a very nice conversion. ;D Hopefully addressing the gasket problem should give you a good reliable VW engine.
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Past: 13 VW Beetles from 1967 - 1974 Bay Window Campers (1973 & 1974) Mini's (1992 Cooper lookalike & 1984 '25 Anniversary) MK2 Polo Coupe S (1984 & 1986) MK2 Polo Breadvan (1981 & 1984) MK4 Escort (1989) MK2 Granada Based Hearse (seriously) Fiat Uno 60S (1986) Punto 60S (1998) Cinq (1997) 1998 Yamaha YZF600R Thundercat 2003 Ford KA
Current: 2004 Ford Focus (barely alive)
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