 Engine rebuild, The reassembly started ! |
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| Valy |
 Sep 10 2011, 10:34 PM
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#41
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Senior Member  Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California  |
WARNING:
Horror pictures bellow. Don't scroll down if you are pregnant or have a heart condition. Finally I split the case. The bolt behind the flywheel was the one I missed. Thanks for the help so far. The bearing pictures are not so pretty. Main bearing are done. Standard size bearings. After seeing the ones that come out easily, I didn't bother with the last one on the crank. The camshaft bearings were German SK and are all junk now. 1 and 2 broke and 3 has much more wear on one side (the bigger half lost its coating and you can see the copper while the other side has still the coating on it. Camshaft shows some wear as well. I'll probably need to replace it. This engine was identified by the Cap'n as one rebuilt by Volkswagen Canada that, as he said, are of questionable quality. Well, the Cap'n was right, no questions here anymore.                  |
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| VaccaRabite |
Sep 11 2011, 07:23 AM
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#42
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En Garde! Group: Admin Posts: 13,717 Joined: 15-December 03 From: Dallastown, PA Member No.: 1,435 Region Association: MidAtlantic Region 
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Looks like an engine that had a lot of miles on it.
Your cam bearing journals clearly need bored out. Can you get + size cam bearings? Get a new cam. Pull all the studs. Have the case checked at the bearings to see if you can still use standard bearings. ALSO have it checked at the cylinder registers to make sure they are still square and not collapsing in the center. If the case is trashed, don't just junk it. I have found it to be helpful to have a split case and crank on hand when I need to understand how something works. Like when I dropped a spring in the engine I needed to know where it would go for retrieval. Zach |
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| JStroud |
Sep 11 2011, 08:37 AM
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#43
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Senior Member Group: Members Posts: 1,463 Joined: 15-January 11 From: Galt, California Member No.: 12,594 Region Association: Northern California |
[quote name='Valy' date='Sep 5 2011, 04:15 PM' post='1534942']
[quote name='Jake Raby' post='1534917' date='Sep 5 2011, 03:30 PM'] The lowermost pic of the oil pump shows a failing pump.. See that idler gear shaft?? Anyway, what are my alternatives for the oil pump. [/quote] This is a question i also have, need a GOOD alternative to the stock pump. My rebuild is on hold this is one issue still not resolved. Good luck with your project, I'd take the case in and get the bores and registers checked before going much further. Jeff |
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| Cap'n Krusty |
Sep 11 2011, 09:06 AM
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#44
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Cap'n Krusty Group: Members Posts: 10,794 Joined: 24-June 04 From: Santa Maria, CA Member No.: 2,246 Region Association: Central California |
QUOTE(McMark @ Sep 5 2011, 06:21 PM)  QUOTE(Cap'n Krusty @ Sep 5 2011, 12:55 PM) I don't see any comments about temperature sensor location in any post other than yours. The type of case has NOTHING to do with oil temp sensor fitment, and the stock one will fit fine. Second time I've seen this misguided notion in the last few days ................ The Cap'n You're right, I didn't mention that. Zach was reading my mind. There ARE some cases which won't fit a stock 'long' oil temp sensor probe. Ran into that problem on a bus once. (IMG:style_emoticons/default/hijacked.gif) The temp sensor installation shown in the picture is aftermarket. With the correct taco plate, the long sensor will fit in ANY T4 case. In that part of the case, they're ALL the same. The Cap'n |
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| Valy |
Sep 11 2011, 03:50 PM
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#45
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
Crankshaft and Rod journals.
Some pictures of the crankshaft and the rod journals. The crankshaft looks fine but the rod journals are not so nice. I'm not sure how those marks got there. The rod bearings are toast. Attached image(s)      
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| Valy |
Oct 14 2011, 01:40 PM
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#46
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
Update:
My machinist finally measured the case and it needs to be aligned bored. Lucky for me, the +0.25 main bearings are just $50 (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/biggrin.gif) |
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| SLITS |
Oct 14 2011, 01:46 PM
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#47
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"This Utah shit is HARSH!" Group: Benefactors Posts: 13,602 Joined: 22-February 04 From: SoCal Mountains ... Member No.: 1,696 Region Association: None  |
The marks in the big end of the rod are from machining - cross hatching from a hone bringing them to the correct size.
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| Valy |
Oct 14 2011, 04:21 PM
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#48
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
QUOTE(Valy @ Oct 14 2011, 12:40 PM) Update: My machinist finally measured the case and it need to be aligned bored. Lucky for me, the +0.25 main bearings are just $50 (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/biggrin.gif) I was happy too early. Those were +0.25 on the crank and I need oversized case (IMG:style_emoticons/default/sad.gif) |
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| Valy |
Oct 20 2011, 01:48 PM
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#49
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
New stuff is starting to arrive!!! (IMG:style_emoticons/default/piratenanner.gif)
Here is what I received today: 96mm pistons and cylinders. Still waiting for the oversized main bearings before any work can be done on the case. Attached thumbnail(s) 
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| McMark |
Oct 20 2011, 02:36 PM
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#50
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914 Freak! Group: Retired Admin Posts: 20,179 Joined: 13-March 03 From: Grand Rapids, MI Member No.: 419 Region Association: None |
QUOTE(Cap'n Krusty @ Sep 11 2011, 08:06 AM) The temp sensor installation shown in the picture is aftermarket. With the correct taco plate, the long sensor will fit in ANY T4 case. In that part of the case, they're ALL the same. The Cap'n Sorry Cap'n. You lose this round. (IMG:style_emoticons/default/tongue.gif) Case on the left is a GE case and the long sensor will bump into that 'skirt/fin' hanging down. BTDT. Attached image(s)  
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| TheCabinetmaker |
Oct 20 2011, 02:51 PM
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#51
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I drive my car everyday Group: Members Posts: 8,335 Joined: 8-May 03 From: Tulsa, Ok. Member No.: 666 |
Is that the top left or the bottom left? (IMG:style_emoticons/default/stirthepot.gif)
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| Valy |
Oct 20 2011, 07:19 PM
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#52
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
QUOTE(McMark @ Oct 20 2011, 01:36 PM) QUOTE(Cap'n Krusty @ Sep 11 2011, 08:06 AM) The temp sensor installation shown in the picture is aftermarket. With the correct taco plate, the long sensor will fit in ANY T4 case. In that part of the case, they're ALL the same. The Cap'n Sorry Cap'n. You lose this round. (IMG:style_emoticons/default/tongue.gif) Case on the left is a GE case and the long sensor will bump into that 'skirt/fin' hanging down. BTDT. Good to know. I may cut that fin down or use a different sensor configuration. I have both the original taco plate with the built-in sensor and a modified non-sensor one, drilled to accommodate a short sensor. |
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| Valy |
Oct 20 2011, 07:42 PM
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#53
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
Those are AA pistons.
Measured the ring gaps in the cylinder (spec values): 1st: 0.432mm (0.35-0.9mm) 2nd: 0.483mm (0.3-0.9mm) Oil: 0.533mm (0.25-0.95mm) Piston ring width (strange, but looks like SAE dimensions) 1st: 1/6" 1.59mm 2nd: 1/6" 1.59mm Oil: 3/6" 4.76mm Piston clearance in the cylinder: Cylinders are 96.00mm and pistons are 95.94mm 0.06mm (0.02-0.20mm) Compression height (piston pin center to piston head) 35mm Piston pin hole 24mm |
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| Valy |
Nov 11 2011, 01:41 PM
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#54
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
Cam is here (IMG:style_emoticons/default/piratenanner.gif)
Lift is 8.2mm (0.323") on each lobe although intake and exhaust lobes have different dimensions. Accounting for the x1.3 rocker ratio this is 10.66mm (0.420") This is a bit lower than the cam card 0.426" (IMG:style_emoticons/default/confused24.gif) The lifters are solid lifters but look a bit like the hydraulic ones. You can see a moving part inside the lifter hold by a C clip. There is no spring and valve behind it. Maybe this will make the valves a bit more quieter. Lifter diameter is actually 23.98mm so it's within spec. My micrometer was not calibrated to the lower outside temperature.  |
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| MartyYeoman |
Nov 11 2011, 02:14 PM
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#55
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Senior Member Group: Members Posts: 1,531 Joined: 19-June 03 From: San Ramon, CA Member No.: 839 Region Association: Northern California
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What WebCam part number is your cam?
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| Valy |
Nov 11 2011, 02:45 PM
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#56
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
QUOTE(Marty Yeoman @ Nov 11 2011, 12:14 PM) What WebCam part number is your cam? It's a custom grind. 224/229 at 0.05" lift. max lift 0.426 |
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| AndyB |
Nov 11 2011, 05:00 PM
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#57
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The Governor is watching me Group: Members Posts: 1,115 Joined: 10-April 10 From: Philadelphia New York Member No.: 11,595 Region Association: North East States |
So thats not a Raby Cam?
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| Valy |
Nov 11 2011, 05:16 PM
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#58
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
QUOTE(Scarlet75 @ Nov 11 2011, 03:00 PM) So thats not a Raby Cam? Nope. I bought it from Webcam. |
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| Valy |
Nov 11 2011, 05:42 PM
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#59
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
Strange but true, the bolts that hold the gear on the cam are not metric.
5/16" diameter, 1/2" length, 1/24" thread. I initially thought those are fine thread 8mm/1mm but was wrong. (IMG:style_emoticons/default/WTF.gif) The rings size is SAE, now this, why is everything aftermarket SAE? |
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| McMark |
Nov 11 2011, 06:57 PM
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#60
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914 Freak! Group: Retired Admin Posts: 20,179 Joined: 13-March 03 From: Grand Rapids, MI Member No.: 419 Region Association: None |
Because the tool suppliers have cheaper prices for SAE tools/machines due to demand. It's costs more to be metric in the US.
This seems like a perfect time to go on a rant. I HATE SAE! It makes no sense and it's a pain in my ass every time I have to deal with it. |
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