iceviolet

Coming on very good, and very quickly! good work! how did you compress the rings to get the pistons back in? with a tool or just by hand?? I will be putting my block back together next week just wondered if you have any tips for installing the rings, look like they might be a pain! cheers :salute:

Not had much time to do much with the rebuild recently due to work and uni. I managed to get the new guides into the cylinder head and i have lapped all the valves in tonight. So i will put the head back together tomorrow. Also managed to paint the block with matt black engine paint. The oil spray jet i was waiting for arrived, all the parts are here now so it is just waiting to be put back together. Busy this weekend so i will have to start next week!! Just a quick question, has anyone any advice on putting the pistons back in?? I have a normal type piston ring compressor, i can see i will need to grind a 7.5 degree angle on this so it goes flush to the top of the block. Is this the best way to put them back in?? Just a few update pics:

how did you clean your gearbox up?? Im going to be doing that soon

from bentley manual: -measure approximately 6mm from lower edge of skirt, at 90 degrees to piston pin axis - maximum nominal dimension tolerance 0.04mm 2.9 pistons should measure 81.985mm as standard

a familiar sight! I think if it is just surface marks they should be fine, the ones i am putting in my rebuild are used ones and two of them have a few marks on them similar to those. When i measured them with a mic, they were within tolerance. Think they can look worse than they actually are. Then again im no expert as this is my first rebuild.

No im a control valve engineer, so have access to tools like presses and machine tools in the workshop.

I made a drift tool to knock them out with, going to take it into work and use the press there to press them back in with. I wouldnt mind a press at home, come in for all sorts of things.

yea i have found this out now, got a copy of ETKA and it states that the parts are discontinued and shows the replacements which are what ive got. Thanks for the response anyway, going to get some more pics of the rebuild up when i eventually get the oil spray jet im waiting for from VW. In the mean time ive started to overhaul the cylinder head, completely stripped it and the valve guides arrived today, so will put them in sometime next week hopefully.

Yes it looks that way. As you say, i also find the staff at the VW parts department very un helpful at times.

There is two numbers, the first number is for the distributor coupling and the secon for the CPS. It states that the CPS is for F 50-P-009 001>> and the distributor type coupling for earlier numbers.

CAM POSITON TRIGGER WHEEL 021 905 163

ok, might just do that, im pretty sure they are compatible, if not an improvement, but would just like someone who really does know for sure that they will be fine, just to confirm it. A mistake at this stage could be costly! cheers

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Quick question about parts: I picked up some parts today from VW, main bearings, thrust washers and oil spray jets. They look slightly different to the ones that came out of the engine though. Would be great help if anyone knows the answers to my questions and could confirm that they are the correct?? Firstly the top half of the new main bearing is grooved like the bottom,but without the slot. The guy at VW said that the shells with no grove in are discontinued now? and these are the replacements? i think they will be fine, if not better as they provide oil all the way around. Secondly the thrust washers, the came off in two parts, a top and a bottom. The new ones are just one piece but slightly longer. Is this the right part, has the two piece washer been replaced by this?? The guy at VW didnt know, and the computer just showed this one piece on both the ABV and the AAA engines?? Also another thing that has irritated me is that i ordered 6 new oil spray jets, only 5 were in stock and i will have to wait for 1 single spray jet from germany, up to 14 working days!!! :bad-words: They are the first parts to go back into the block aswell!! Take a look at attached pic, be greatful of any feedback! cheers guys.

ok, yes ive read about that before somewhere, think you had to do something like that with some older VW's. Run for a certain number of miles then tighten down again. Im not going to get the ARP head stud set, mainly because they are so expensive. Just going to get the con-rod bolts. Do you know anything about the oil spray jets??

Quick update: I got the block back from the machine shop the week before Christmas, been quite busy so have not had any time on it until this weekend, managed to clean up the exterior of it and primed it ready for a top coat of paint, matt black i think. Got a good set of pistons to go in now, with a helping hand from Stan24V who donated me his old pistons :notworthy: . I have got a set of piston rings which the machine shop supplied me with. So should be good to go when i get the main bearings and new con-rod bolts. Going to get the bearings from VW and i think im going to get ARP bolts. I was thinking about getting everything from the states but probably not worth the hassle and not much difference in price now with the way the £ is, the shipping costs and also the customs charge :bad-words: . Does anyone know if the oil spray jets should be replaced?? I cant seem to find anywhere to buy them on the net?? Few update pics:

Yep battery sounds most likely. Could be a seized starter though, had this problem with mine a while back, got a mate to turn the key and keep it held, whilst i bashed the starter with a pole, the shock just freed it up and it fired into life! worth a try!

Had the same problem with my mirrors, just clicking and only one working now and again, definately the contacts in the switch. opened it up, bit of fine emery cloth or brillo pad on the copper contacts and it works a treat now, not had any problems since.

Oh well. the next time the gearbox will be out is when ive rebuilt my engine to go in with a spare gearbox. So ill just have to put up with it. :(

Yes please mate, they would be of much use. Ill cover the postage costs, pm me details. cheers

Thanks for that, not found that website yet. Im going to be using some used 2.9 pistons that i already have and just get the rings for them. Have you bought much from the states?? if so whats the deal with the customs payments??

I have a noise thats developed and im pretty sure that it is the clutch release bearing, high pitched noise and if you just rest the weight of your foot on the clutch pedal and slightly depress, the noise goes away. The clutch and bearing were replaced not so long back, about 6 months ago. Is there any way of stopping this noise??

Quick update, pulled my finger out and decided to go through with the first idea of getting the 2.8 block machined. Managed to get the pulley bolt out of the crank, used a torque multiplier, came of easy with that. So I have got the block down to its bare bones and have been quoted £120+VAT for the re-bore to 82mm and the company said they can get me the rings for the 2.9 pistons aswell but not got a price yet for those. So hopefully going to get the engine to them within the next week or two and i can get on with getting the thing built back up.

I tried the water thing with mine too, didnt arc and the resin looked fine, no splits or cracks. I think on mine, one of the actual coils inside the unit had gave up the ghost. How recently has it been replaced??

Yes its completely standard.