Engine restoration pics

Big lumps of metals and spanners.

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fairwynds
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Engine restoration pics

Post by fairwynds »

Hi all
I thought Id post a few pics on the site, as, although the engine's complete now, I didnt get chance to post the whole thing when I was undertaking the work. They may encourage some folk to 'get their hands dirty' and show what can be achieved by a relative novice at home...?

Vans history - owned 6 yrs, bought with 53k on clock. Exhaust replacement was the main reason for dropping the engine, as I had been quoted up to £1000 at a fitters!! :shock:

Before I did so, I ran some compression tests, and found that one cylinder was low (which later explained an annoying backfire on overun).

So, the work began....

before the work started....
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG1656.jpg[/img]

[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG1661.jpg[/img]
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fairwynds
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Post by fairwynds »

engine being lowered, as everyone had told me - it was suprisingly easy!
[IMG:800:600]http://i98.photobucket.com/albums/l261/ ... MG1686.jpg[/img]

..and onto drive for a good wash!
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG1703.jpg[/img]

[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG1711.jpg[/img]
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fairwynds
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Post by fairwynds »

onto the workbench, for the start of 3 months labour! (was only supposed to be a month!)
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG1717.jpg[/img]

..and guess what? 6 out of 8 exhaust studs snapped off! Shouldve used heat! The heads were packed off to a good engineering firm who worked their magic!
[IMG:800:600]http://i98.photobucket.com/albums/l261/ ... MG1736.jpg[/img]

heads all clean and getting sorted.... and I found out a burnt/worn valve was the culprit for the low compression and backfire....
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG1789.jpg[/img]
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG1792.jpg[/img]
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fairwynds
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Post by fairwynds »

engine cleaned meticulously, with LOTS of elbow grease!

FROM THIS....
[IMG:800:600]http://i98.photobucket.com/albums/l261/ ... MG1894.jpg[/img]

VIA THIS......
[IMG:800:600]http://i98.photobucket.com/albums/l261/ ... MG1895.jpg[/img]

TO THIS......
[IMG:800:600]http://i98.photobucket.com/albums/l261/ ... MG1898.jpg[/img]

AND THIS.....!
[IMG:800:600]http://i98.photobucket.com/albums/l261/ ... MG1899.jpg[/img]
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fairwynds
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Post by fairwynds »

so, having done that, I figured, might as well get the gearbox out as well, for a bit of a spruce up.....!

BEFORE.....
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG1999.jpg[/img]
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2001.jpg[/img]

AFTER.......
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2004.jpg[/img]
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fairwynds
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Post by fairwynds »

engine bay prepped....
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2045.jpg[/img]

tappets all clean and tidy...
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... 2205-1.jpg[/img]

...and heads clean and replaced, new VW rings too
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2213.jpg[/img]
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Post by fairwynds »

I found the fuel pump pedestal had snapped, and had to fashion a 'puller' to remove the remaining bits....
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2237.jpg[/img]

...and the choke heater was faulty, found to be the tiny heating element wire inside snapped...
CHOKE BEFORE...
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2235.jpg[/img]

CHOKE AFTER....
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2275.jpg[/img]

and the choke in bits....
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2274.jpg[/img]
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Post by fairwynds »

and after a good few weeks, i finally refitted the gearbox....
Lookin good...!
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2242.jpg[/img]

and engine ready.....
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2253.jpg[/img]

[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2300.jpg[/img]

MY FAVOURITE VIEW!!!!!!
[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2302.jpg[/img]
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Krisis
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Post by Krisis »

NICE WORK 8)
Its not broke? fiddle with it until it is, then you can fix it
Oh and the name is pronounced CRISIS
CS/JK/CS 1.6 diesel on a DY/DY/DU 4 speed box (3rd engine & gearbox now fitted)
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Post by fairwynds »

and, VOILA!!! Finished! Took three months of most evenings, but an awful lot of that was cleaning! :D :D :D

[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2424.jpg[/img]

[IMG:640:480]http://i98.photobucket.com/albums/l261/ ... MG2421.jpg[/img]
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Post by fairwynds »

Cheers Krisis
have had months of trouble free motoring so far! Yay!!!
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Post by Andyvandy »

Great job.

It looks wonderful!

Reminds me of the time I rebuilt one of my motor bikes. everything stripped down, cleaned, fixed/replaced and finally re-assembled and looking beautiful

Will you do mine now please :!:

Andy :D
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Post by Steve P »

Thats an amazing difference :shock: .
I love getting my hands dirty, I keep putting off doing that to my engine, but after looking what can be achived. WOW.
Tia is a 1980 2 litre air cooled viking roof
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Post by Wavehead »

Good work mate. I did mine (diesel) 5 years ago and totally re-built it.

Like you I gave it a thorough clean and spruce up knowing full well it would not run any better but certainly gives you a warm contented feeling and is a visible representation of the hard work you have put in.
For info 5 years and 15,000 miles later and she is still purring as sweet as a purry (albeit diesely) thing .... well worth the effort.
If at first you don't succeed, destroy all evidence that you tried.
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Post by R0B »

well done.. :wink: gti madman will be well jealous.when he sees that engine and gearbox...
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