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Well I took the car down for an MOT so that there was no question of it being mid engine swap at MOT time and the test lapsing. As expected it passed. The amount of time I have spent under, in and round the car recently I think I would have cried if it had failed. So the plan this weekend, as its a holiday weekend is to try and get the engine in and running but there is one problem. If you look at the pics of the engine build you will see I have been doing it on a workmate. So how the hell am I going to lift it down by myself? One of the small details I need to address but I will let you know how I do it and how it goes. Dave.
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I have managed to rope a mate into giving me a hand lifting the engine off the stand tomorrow so today I pulled the old engine from the car and swapped over the coil, carbs, ballance pipe and the last of the tinware. Might as well be heavy if I'm getting a help ;-)
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I have spent the day working on the car and good news, the engine is in; The bad news is that allthough it is running there seems to be very little oil pressure. I don't know at the moment whats wrong. The oil light comes on at idle and given a bit of gas the max pressure I got from it was 1.5bar so something aint right. Thinking it might be the pressure relief valve I opened it up to have a look and also opened a scrap case to compare what was in each. The spring on the left came from the scrap engines relief valve and the spring on the right came from my new engine. Thinking that migt be the problem I fitted the longer spring in my new engine but no change....... Still low pressure.# I'm not quite sure where to look for a solution at this point. Dave
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mrj
Posted a lot
Posts: 1,662
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that's not nice to hear.... i would guess the oil pump ? I wouldn't worry about the spring, they changed so much on the cars, there are certainly different valves around...
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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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I'm going to try a later "T" shaped plunger in the release valve and if that dosnt work it looks like the whole lot is coming out again to get to the pump.
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When I came home last night I was feeling pretty curse word off and the problem with the oil pressure was niggling away at me all night. So I was back round at the car at 11am this morning to try and solve the problem. I figured it had to be the relief valve as the pump was pumping, just not pressurising. So I remover the valve and smeared a little grease on the top of it; Then pushed it into the relief gallery untill it stopped then pulled it back out. The grease wasnt disturbed so the valve wasnt closing properly allowing the oil to bypass the cooler which meant no pressure. So I decided to clean out the bore which wasnt easy as this is all I could see when lying on my back looking up; I masking taped a bit of sandpaper to a drill and fitted it to my die grinder before running it up the bore. After a clean the valve pushed in about another half inch so reassembled it and gave it a try. Success, I got pressure So without hesitation I went for a test drive and it runs great. Only problem now is the extra pressure made it obvious there was a small leak at the bottom of the oil pump which meant I ended up taking theengine back out, dismantling the fan housing and fixing the leak. By 8pm tonight I had it re-assembled and back in the car. I'm getting 2 bar of presure on start up settling to 1 bar as it comes off choke, 4.5 bar max when revved and no leaks. So tomorrow I want to re-set my rocker clearances as it is a bit tappy then take it for a longer test run. All being well thats the engine ready for running in. Dave
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Tonight is not a good night. Mojo is at an all time low. What started as a bit low oil pressure turned into no oil pressure after the test run so looks like strip down time, I'm so curse word off right now........Anybody want to buy a fasty? On the plus side I did run it long enough to make a comparison video between the old exhaust and the new exhaust (it sounds better in life but you get the idea). So I'm off to see how expensive another re-build will be and if I can do it in time for the Scottish VW owners show in 2 weeks at Biggar. Dave.
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Samage
Posted a lot
Posts: 1,467
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Damn, this isn't good news at all! Still, chin up, it'll be worth it in the end. As I've repeatedly said, this is a top resto, it's be criminal to give up now!
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Cheers Samage, I'm not quite at the giving up stage so you will all have to put up with these never ending updates. My thought today was that there was a possibility I had crushed the oil cooler seals so to make sure I removed all the tinware on the left of the engine and the cooler to check. My thought today was that there was a possibility I had crushed the oil cooler seals so to make sure I removed all the tinware on the left of the engine to check. When I re-assembled the engine it was pretty much the same but the pressure was settling at 0.5 bar with no "light of impending doom" coming on on the dash so I decided what the hell, take it to clubnight and if it dies on the way I'm no worse off. Oil pressure didnt drop less than the 0.5 bar appart from when I got stuck in traffic pointing down hill. I still want to do some more to try and increase pressure so I'm going to try and get hold of the later pressure relief valve and change the oil to a 15-40 mineral as opposed to the 10-40 synthetic thats in just now. Hopefully this will help but I have decided to try and persevere with this engine rather than chuck it and start again. Dave
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I went to get parts today but had to order them so they should be in tomorrow. GS&F only list one pressure relief valve so what you betting its the wrong one? (thanks to Pootle from the west of scotland club I know exactly what one I need now, cheers mate). I will also collect different oil and change kits tomorrow. As this is a pretty boring update I thought I would share what is quite possibly the weirdest paragraph I have ever seen in a haynes manual; Now I just removed and fitted the oil cooler with the engine in the car so who the hell is coming to take me away??? Keep your fingers crossed that the plunger I pick up tomorrow is the right one and I will let you know if it cures things. Dave.
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mrj
Posted a lot
Posts: 1,662
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i keep my fingers crossed, want to see that car soon in the flesh.... have similar feelings at the moment, as my "new" engine for the van is loosing some fluid, looks like oil (i could live with that)... but my TL project has moved a bit forward, collected some panels today (in total 5 wings, 2 doors and two bonnets.../all sandblasted and primered), gonna do some work on my TL on the weekend....
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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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May 10, 2008 19:23:52 GMT
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Finger crossing didnt work I'm affraid, I'm suffering another mojo failure again tonight. I was half way through removing the engine again when the thunder started.
Oil pressure is getting worse, even though I fitted a bugpack oil pressure booster kit and changed the oil so there must be a bigger problem.
Tomorrow I will be fitting the old engine with the new exhaust and getting it in the car as I think the new engine will be stripped right back to see whats going on inside the case.
I am considering buying a new case and crank from GS&F and attempting to get it together for Biggar in 2 weeks but I will need to price it up and see if I can afford it.
On the plus side I got a call from Karmann Konnection yesterday to tell me the bumpers I was told would take 3 weeks will be here Monday......11 weeks later.
Dave.
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May 11, 2008 19:51:12 GMT
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I have admitted defeat, the old engine is back in the car for just now until I can investigate what is causing the low oil pressure.
I did however swap the exhaust onto the old engine, couldnt leave that sitting in a box after hearing how nice it sounded.
Dave
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May 12, 2008 18:40:16 GMT
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I got the old engine back in yesterday, it started first time and sounds sweet so maybe I should have been happy with what I had (even if it was loosing power on 2 cylinders).
My bumpers arrived this morning and with the money I spent on them I was hoping for better but its too late to return them now as I need them on for the show.
Painted the backs of them this afternoon and taped on the black stripe through the middle so hope to have them fitted tomorrow.
Dave.
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May 14, 2008 18:12:50 GMT
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Bumpers are on and looking good, I still have some issues with the quality but I will deal with that after the Scottish VW show at Biggar in 2 weeks. Dave.
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Rico.
Part of things
Posts: 226
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I hadn't planned on going to Biggar but I might just go after all to get a nosey at this!
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May 15, 2008 16:52:51 GMT
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Cool, if you want to ask about it when you get there I will probably be at my marquee (route 9 autos) selling vans so drop by and say hello. Dave.
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G4vBr
Part of things
Posts: 200
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Hi Dave, just read through the complete thread and the resto you've done is amazing mate. I was a member on VZi and remember seeing you post up about the accident, but I fell out with aircooled VW's and hadn't seen anymore on your car until today. I'm very very impressed! What paint did you use...is it 2K or cellulose? Only reason I ask is I'm planning to repaint a couple of cars this summer and I'm weighing up beteen the 2. When I got to this bit it brought back some memories: I That really is a strange bit of the type 3 manual! I also managed to changed the cooler seals in situ and no men in white coats appeared. The whole manual seems to have a 'vibe' to it IMO, perhaps they were under the influence of some recreational additives when they wrote it?! To round up, congrats on a top job and chin up with the engine, I'm looking forward to seeing some high speed jumps like in your avatar! ;D Cheers, Gav
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May 16, 2008 12:02:30 GMT
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Cheers Gav, glad you like it and thanks for the kind words.
I am sure the paint is a water based acrylic, Mick was the brains behind that so I'm not 100% on the details but as 2 pac is being phazed out his workshop is allready working with the new system.
As for the weird bit in the manual I had 2 ideas to explain it. 1 was for copyright. Add in an few errors or strange paragraphs so that if anybody rips off the copyright its easy to proove origin
or
2 was that the engine is so similar to type 1 the writers added in a few weird paragraphs so that they got paid twice for the same thing.
Dave.
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Not had an update for a while but things are still happening, just a lot slower than they were. As the old engine is back in and running I have been driving and enjoying the car while its sunny and its going great. I am still going to change the engine as having covered 116000 miles and with compression down on 2 cylinders its time for a change but for now its still going. So I got the flywheel off today and I can now continue with the tear down. I have sent off an e-mail to Karmann Konnection regarding the bumpers so I'm awaiting a response. As there is now signs of rust after being on the car for 4 weeks, the pitting and the twist you can guess I'm really unhappy with the bumpers. On the Sunday morning at the Scottish VW owners show in Biggar I met up with a writer, Bob Weir who took a few pics for an article he is writing, one of these appeared in the motoring section of the Scotsman 2 weeks ago and readers were asked to guess what the car was. Last Friday the correct answers were printed; The reporter also took this great picture of my car; More updates soon, Dave.
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