Big issue ! Now fixed,thanks

[MrD]

That`s what i thought,it ran but was lacking power

[Nate]

i managed to get the timing 180 out on a passat 2E. it would run, but it wouldn't rev up. sounded awesome though. it must have been firing while the inlet was open. previous owner / garage had put a timing belt on it and got the pulley for the dizzy out, so just swapped the plug leads on the dizzy to compensate. took aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaages to get to the bottom of it

[MrD]

Like in the vid i put up here ?
Really starting to think mine might have been timing issue,
All my order was here waiting for me when i got home,also bought some carbide burrs (£3.57 for 5) for porting,only the short shank jobs,but only going round where the gaskets are.
Mine ran but it sort of felt empty when revving if that made sense,revved way to easy,took a while to settle back down,but just didn`t sound right,oh well if i find i have had the head off for nothing,then i will chalk it up to experience,got a Kr head to play with ,so this will be good practise

[MrD]

Well been a busy boy today,went and bought the correct valve spring compressor,and stripped the head down ready for porting

All went well,i didn`t go too mad,just smoothed things up a bit,removed the lip from the valve seat insert,matched it to gaskets,and gave it a little polish,all valve guides are nice and tight,not going to bother with the stem seals,only need this engine to last me a few more months..












Why did all the ports have numbers stamped into them ?

[Nate]

no idea. what were they?

[MikeH]

I've seen that used before to identify the die number used in the casting - where there are several different casting dies being used - to monitor the quality that each casting die results in. I expect the number is cast in, rather than stamped in.

[MrD]

Sorry yeah,they will be cast in,was quite surprised at the poor quality of it if i am honest,there were lumps and bumps all over the place,also the inlet has some big lumps of cast there,need to get down it with a bottle brush,as it`s pretty manky.
Didn`t get chance to drop it off today,but can`t grumble at that,as i have made some decent money.
Will be dropping it off before my first job in the morning.
Not sure if i am going to bother with a crack test (Would i need to re fit the valves for this ? I assume so ) Have cleaned the chambers up nice,and inspected with a mag glass,and they all look spot on.
I am going to be in the realms of interference,if i go too far with the grind,think i may just tell them to take off what it needs to be flat,as the valves come out further than the face of the head as it is.

no idea. what were they?

a 4 a 3 a 3 and a 2,on the intake ports

[MikeH]

With a lumpy cam, you're probably already running an interference engine. Also, you could do with a bit more compression to get the best out of the cam - maybe 10.5 or 11:1

[MrD]

Hi Mike,your most prob right there.
Just been and collected the head,£52, he took 6 thou off it,said one corner was a bit lower than the rest of the face,spoke to my bro in law,and he said it may have been a valve sealing issue,on 3,and looking at the seats,there are a couple that are quite pitted.
Will no if it`s fixed over easter i suppose,next couple of days i have a lot of work booked,and as i am doing this on a driveway it`s also dependant on the weather,my days of lying under cars in the rain ,have long since passed !!
Saying that though,i really miss it,helps me unwind ,going for a blast to clear my head...

[MrD]

Righty,i put the head back together yesterday,i noticed all my tappets were really hard to push down by hand,apart from one ? Is it possible i may have a problem with this one ? Never had a prob with them pumping up,or being noisy,will it be ok do you peeps think ? Or would it be worth replacing it before i put the engine back together ?

[walkinginperu]

Did you prime all the tappets first buddy? (squeeze, then release while under some oil) Mine were quite stiff to push down too

[MrD]

Nope didn`t prime them,took them all out,gave them a wipe,put them in a tub,then when i put it back together yesterday,there was just the 1 that felt spongy,might be why,will bang the head back on later this week,and just keep my eye on that one,that`s if it stops raining

[MikeH]

It might be a bit sticky and losing pressure, but I wouldn't worry about it, if it wasn't tapping before.

[Chaps]

Strange this thread, it all sounds like it should be working ok, but cant understand it myself.
Piston Rings on Cyl No3? could explain the drop in pressure, and also could be pressurising the crank case and blowing out of the breather pipe? was your intake pipe/throttle body all oily? I cant think of anything else other people havent already mentioned?

Nothing better than getting a clean shiney head back from the machine shop... hmmmmm, I miss my attempts at head porting and lapping valves!

Good luck Mr D...

[MrD]

Thanks Chaps,and everyone else who has taken time out to comment,i must say it`s baffled just about everyone i have mentioned it too,inc engine builders etc !
The shop that did the head gave it a dip for me,which i was not expecting,one comment from another mate ,who said possibly a crack somewhere,i have looked at it very close,after the clean,with a mag glass,nothing !! Also mentioned it to the shop that skimmed it,they looked and said,it`s fine,the head was slightly lower drivers side at the back,where the manifolds are,but they only had to take of 6 thou = 8th of a mm.Head place looked at the old gasket,and said possibly a prob with it in one spot.
Valve seats were a little bit pitted in places,but not really enough to justify the comp readings,as they didn`t take long to lap in,and only used fine paste on them.
If it was rings then it would by blowing by,a lot,and not sucking,the bores are all nice and mirror like,no scratches etc.Intake system all clean,manifold bit grimy but not too bad for 230+ miles,it only smokes a little on full throttle in 5th,when i proper hammer it,but then it`s burning a lot of fuel,does not use oil or water ?
Going to crack on with it on Sat,and will hopefully get it up and running again,and hopefully it will sort it,won`t be able to drive though ,until i get new tax disk,have been putting it off as no point if it`s not going to be running right.
Have had to call mr tax man,not happy,as had to set up d/debit for £400 a month,until Jan 2011 !Plus i will need to put away 20% of what i earn for the bill which will arrive in Jan,so it`s going to be tough finding the money to build up the 9a,won`t be paying any cash into my account now though,but then i won`t be able to claim it back on expenses either,catch 22

Oh and the valve guides were tight as a gnats chuff,could not move valve side to side at all,bloke in engine shop said they may have been done,as even he commented on them,he said his bro had a golf with the same engine,and there was loads of movement on the guides in that,and said no point doing them...
Have also got to take the rubbish pooburg of the wife`s mk2 golf over the weekend,my mate has just put a set of Webber 40`s on his Westfield,so i have the Webber that came off that,nice shiny K+N filter too,only gave him £20 for it,hope it will fit ok,looks like there are a few electrical connections on her current carb,and not sure what to do with them