Rams

To replace tappets is a fairly involved job if you are only replacing the tappets, the process is simple but if your removing the cams it only takes a few minutes to put new ones in, I would be inclinded to do them. Depends how long you want to keep the car as well....

Poly bushes arrived today, new clutch spring clip arives tomorrow, started cleaning the gearbox properly, there was lots of dirt inside. New rear top mounts, picked the last one up at TPS, now not available. The stealers may have stock for anyone needing them, or use poly top mounts.... Had a result with the tank straps, they have come out really well considering they were totally rusty. The powder coaters did them for me for a tenner, blast and powder coat and all the sub frame, cross member, rad support panel, various clips and brackets, wishbones, water pump pully etc for £130. Thats a good price I though and a very good job. Ordered some new braided fuel hoses and clips from Demon Tweeks today and should arrive tomorrow, some new rear bumper bolts, new power steering fluid to complete all the oils. New release bearing going to be fitted as well as ive become a nob and started replacing bits which dont need doing! Need to change my rocker cover hasket as the plastic one is definately different and hasnt got the little semi circle part that slots in.... I called tps today and said, try looking at a gold rocker cover and he said they list the same part number and hes given me what it states for the car so need to find out what the part number is for the metal type.... Pics up soon once its all unwrapped

Managed to order 4 springs, so if anyone needs a spring I will have a couple spare. Also, the release bearings are available individually and have ordered one even though mine is fine so if someone needs a spare correctly working release bearing, I have one....

Anyone know the correct part number for a metal rocker cover gasket?

Ahh, I havent opened the new gasket so hopefully they can swap it. Nice one.

I ordered a new rocker cover gasket for the plastic type cover, then saw and bought a metal one from ebay and wondered if the gaskets are the same? I would think so?

Whilst cleaning my gear box today, i found the broken spring retainer inside in 2 bits. Do you think this spring is available? Will contact tps tomorrow as it was gone 6 when I realised. Also, are the release bearings available separately?

Cheers peops, Im glad its cool as to what hes doing and said he always drains them and wipes the cam lobes etc as posted above. Engine will be back together tonight. :clap:

A few pics

Hi all My mechanic and I were at the workshop tonight and we were at the point of replacing the tappets with the new ones I've got. I said to him yesterday, we need to put them in engine oil over night to fill up.... He then looked at me and said why? I explained the forum etc advises to leave them in oil to fill up. What he actually did was remove the valve from the new tappet and drain the clear lubricant from inside and put the valve back in. He said he was taught by a superb mechanic to install tappets in this way and has never had an issue. He also said something about the movement of the valve once fitted can adjust before filling up... Anyway, thats the long and short version I think of what he said. Once he installed the new tappets he finger wiped the surrounds with oil as a form of lubricant. I'm interested to hear peoples opinion as I have gone with his method. Will clearly find out what its like once its fired it. Rams

What sort of ride height did you set the coilovers? Have you checked the cv joints/engine for any oil leaks? Just to rule them out...... However, I would agree that if theres oil weaping then the kw's will need rebuilt and kw should do that if they are still under waranty? What length of waranty to they come with and have you read anything to say that oil seaping is normal due to the cum discharge, bla bla bla? :roll:

Sure, it will be fully eibached up with Arbs, all new engine mounts, poly wishbone bushes and all new top mounts so it should be good! It's cost me and arm and a legg so it better be! lol Also, I will be on wide stance with large spacers which will make a difference to how it handles but happy to take you for a spin. My ebay purchase arrived today! Just the Poly bushes to arrive tomorrow and need to order lods of sanding discs and Abranet sanding strips, supposedly very good product. Went to see my bits at the powder coaters today and they've been really fantastic, managed to get me in on there black powder run early so collecting them tomorrow lunch time, so by the end of this week, the engine will be back together purring like a tiger. Got to finish polishing the rocker cover tonight and tomorrow. Other than material difference, are there any advantages of running the metal rocker cover or the plastic one? Ive heard they are a bit louder? Managed to get my mechanic a new garage, much bigger place so hes happy and he picked up the keys today, just been informed. So soon he will have a 2 poster ramp and plenty of space. The deal I made with the mechanic was, if I sorted him out with a new premises, I could have a corrado corner!

I ordered the coilovers via Corby Motorsport on line, priced matched him to his ebay listing but hes since then put the price up slightly. Gaz Gold, with dampening setting with the spring rate they recommend. I purchased all my parts for the timing overhall from TPS, cant quite remember the cost, i may have mentioned that when I took the pics of the parts when they arrived. If your buying tappets, use euro car parts, INA supplied, even though they didnt list them as INA, they were listed as Febi Bilstein. Half the price of TPS. I think most of us get some form of inspiration on this forum, so its welcolmed by the fact I have inspired you. So what have you got planned?

GAZ Coilovers, Plus the pic of the oil leak as who ever removed the timing covers before to check wear maybe forgot to put them back in. Thats the oil sludge just by the end of the head gasket.

Love it.... The man has skills

I like the sound of this...... Once my car is painted and I have robbed Barclays, I will be contacting you

Hi, all bits are genuine vw and using the mk4 tensioner/ guide, think its just got a different coating which is stronger. My new number plates arive tomorrow :D Found some really decent powdercoaters, local to Poole, they are doing a good job for me and have been quite sensible with the price... Hopefully they will be ready early next week as they managed to slot mine in with a batch they were rolling through so I could put my car back together quicker! Top blokes. They took a real interest in my project and just made me feel really good and satisfied. Theres not many places that look after customers properly!

The top tensioner pad has wear, its worn through to the metal rivit on one side so definately ready tobe replaced. Ive taken some pics tonight and by tomorrow the new parts will be installed. Picked up the parts that were on order, just waiting on the stuff being powder coated, but next week she will be fully serviced, new timing gear and INA tappets. Gaz coilovers arrived and they are just going to have to wait till the car is painted. My new metal rocker cover should arive on Monday, ebay purchase. Will be polished up to match manifold. When my guy was taking the bits apart, there was an oil leak noticed where the 2 bolts that hold the top timing chain cover were not there. This is the top cover. So someone has had it apart before and forgot to put them in! But that explains the oil weap below! Will get some new bolts for this.

Cross member, subframe, wishbones, fuel tank straps, engine mount bracket etc stripped, wishbone bushes removed, ordered Polly bushes from Venom for them, my mechanic picked up that the old wishbone bushes arrows were not inline with the rubber/arrows. so I know the the new ones will be fitted correctly. New oli and filter ready. The water pump pully is being blasted and coated. Gearbox off tonight and clutch looks in excellent condition, practictally new infact, will get a pic tomorrow. New sump, gasket, final engine mount so all 3 are now new. Near rad fan support bracket and rubbers, the rh side bracket is no longer avail, so mine will be powdercoated. New water pump, spark plugs and rocker cover gasket. The timing chains and tensioners etc are being done tomorrow, so catching up with the mechanic with the camera and lend a hand. Coilovers set to arrive Friday and can be fitted by the weekend. Will make a start de greasing the engine and cleaning the engine bay, I want to do so much more but have to calm down. Im saving to buy a daily! I think my off side engine mount was missing a centre bolt which may have been my vibration through the car/gear lever under load. The It still looks like a sorry state, had to delay the prepper as the powder coating is going to take a week, possibly a week and a half. So im 3 or 4 days behind. I really am looking forward to seeing her all back together. The front set of H and r adaptors should arrive in 2 weeks, but need to finish the d90's that im polishing. Its just the rim edge, ive started and nearly finished 2/3 but to get them looking nice, I might just get them professionally done? Will see? Some of the items ready for powdercoaters,

I had similar issues with my car, there will be water ingress somewhere, so if your arch is bad, then somewhere connected with the inner arch or the cill is where the ingress is happening. If you get your car on a ramp or axel stands, give the underneath a poke and tap and see where your metal is soft. I had to cut out any old metal and replace with new, etch prime external paintwork and new underseal/bond seal the inner arches. Then look at getting your paint work done. Otherwise, the rust will return and you will have to do it all again. I almost missed a few spots doing mine, I had to grind off all the underseal to the arches as they were being flared and when the arches were being hammered to flare them, it was then where I saw the weak points. If you take your time, in the obvious places by tapping the inner arches etc, you will find the spots. I had a section missing from the rear corner of the cill and water had just worked its was back and forth. Check also for any damage under neath the car, signs of splits the underseal and get them all nicely sealed again. Its difficult to say how far to go without seeing the rusty parts your mention. I know how you feel with rust on the C..... So good luck with getting it sorted

So the engine came out tonight, I did 75 percent of it which has made me happy. I really enjoyed doing it. Now going a bit further and powder coating teh sub frame and cross member and wil do as much as I can to tidy the engine bay and hopefully paint the block? Ive taken a few pics of the process, the new INA tappets arrived. Ordered them from euro car parts, although the website only had febi bilstein and another make at 8.00 something plus vat each one. After reading some posts, it said that the INA were factory VW ones and the best ones to use. I checked the packaging today and to my delight, they were INA and not the febi ones. TPS wanted £21 each tappet and Euro came in at 8.00 plus vat each one, so a massive saving there.

The rado goes in tomorrow for new timing chains, engine mounts, tappets, oil change and filter, new spark plugs, new main engine seal, new gear box oil and coolant. So a fairly extensive overhall and the following weekend, she goes in for prep! Finally feels like im getting somehwere. The h and R adaptors have turned up, 40 mm on the rear and the fronts are on ther way which are 35mm. The Gaz coilovers should also arrive next week and they can be fitted just before the prep work. Ive also started polishing the outer rim on the D90's and i have to find some time to finish these. I will polish them up and get the painter to paint the middle in mystic Blue. The stainess door poppers are now in and the door comes out perfectably. It also makes a nicer sound when closing the door shit. The glass is coming out and just hoping it doesnt break. Theres light surface rust where I removed the rubber and want to make sure everything is cleanned off and will result in a nice finish. I think after the engine goes back in, I won't post any more pics till its preped and finished. Boy I cant wait. Its been far to long driving my old Transit van everywhere and feeling like a pikey!

Have you got a close up of the mk4 washer jets? How are the doors when opening? Ive ordered those thrsuter kits as I have to use 2 hands to get in.

The car is looking smart, although I spotted some residual polish on the drivers door edge! :lol: From what I can see the paint looks excellent. Very nice. you must feel proud of what you've achieved!

We will see what happens..... I do feel that the restrictions will become much stronger, coupled with the goverment wanting new cars sold witch are more economical and less damaging to the enviroment will penalise people like us. They are shafting everyone else at the moment! The scrappage cars that were taken with a goverment incentive can not be sold, so there are thousands of decent cars out there where only the engine and box can be sold so they have cut their nose off despit their face imo. The last comment about MOT'ers testing whats on the car, like the chap said, if you have no windscreen they cant fail you on that so there are large gaps / legislation on MOT's so why wouldnt they say, the car has to be fully equiped with a windscreen etc? What every I or we think, i can bet things will get tougher and at least we can prepare and im doing that by keeping most of what ive taken off in the event of major changes. Also, they are bound to come in handy at some point. I hope its all hype and no go anyway,but wanted to let people jnow of my news via an MOT tester. He is having new ramps installed and VOSA have to sign it off and from what hes hear from them, its bad news for boy racers, ''quote''