THIS IS A MUST READ.. for Aircooled CU owners...

[Rusty blue bottom]

I shall start by saying that I am undertaking a complete overhaul of my 2.0 engine.
after stripping down we realise that a new camshaft is needed , so I go ahead and buy one with out the wheel, bolts etc.
first when we go to replace the camshaft we realise that the bolts for the modification are not included which we thought was a bit strange to start with so I call the people up .
speak to someone who has no idea what I am after and after about ten minutes he says " can I call you back sir as I need to find out more about what you need" so I say yea no worries. wait for about 40 minutes no call back so I am running late I go to my friends where I have the bus on the ramp and engine in pieces in their workshop.
sit and ring from there to find out what is happening this time different person who seems to have his head screwed on finds the relative bolts that I need and after monies have changed hands he says be with you tomorrow fine great we can move on with the rebuild.
anyway we grind off the rivets on the old camshaft fit the new bolts line the gear in get the case back together tighten up and leave for the following day before we torque up etc.
so... we check to see if the gears are moving nice and smooth and hold on its stuck in a certain place????
whats going on ??? after we realise that we put back the oil pump and then we have the problem of the gear getting stuck so we take off the oil pump to realise that the so called bolts are restricting the movement of the running gear actually the have hit the bolts of the oil pump
so I call back the VW specialist (Vw heritage) and ask if they have had this problem before and I speak to another different person who says then " o yea you have to take back the bolt heads by fifty percent " im like you what he says " yea on the 1600 and 2.0 litre you have to do that on the modification of a new camshaft... we are all there sat with our mouths open flabbergasted to think that what could of happened if we had not even bothered to check the gear and put the engine back together only to turn over the key and to knacker completely the engine and waste the last month we have spent on and off doing the overhaul not to say the cost of replacement parts etc...
the other thing is I am very lucky that I have good friends who have a lathe to hand so we could actually reduce the so called bolts 50 % and actually get on with what we are supposed to be doing .
with no warning of this from them he was so blasé about it . why could they not put a little piece of paper telling us we had to do this I do not know or pre warn us that we need to do this to modify the new camshaft we are disgusted.
anyway I am putting this out to everyone just to make sure that if you are replacing a new camshaft make sure you get the right bolts for the job as these were clearly not fit for the job unless you have a lathe to reduce them to the correct size.
my good friend Neil went on the net this evening and has found the correct type of bolt that we should have used in the first place which are half the price.
any way rant over hope to have Rusty running with in a couple of days and things should be ok.

PLEASE CHECK YOUR WORK FREQUENTLEY AS THESE THINGS DO HAPPEN AND YOU WILL BE SORRY.

[BOXY]

[paulandchez]

Good reminder, I found this out during my rebuild http://forum.club8090.co.uk/viewtopic.php?f=37&t=141607" onclick="window.open(this.href);return false;

Always pays to turn engine over by hand after every new bit goes in

[sarran1955]

Hello,

That is why I asked what you had bought.....

Look at the image and you will see the socket cap screws and washers that are used..

WITH LOCKING COMPOUND...



I hope you paid attention to getting the end float right.. ie reduce the flange on the front cam bearing..

Hydraulic or solid lifters..

Cordialement,