Engine overhaul

[jeffj]

Turned attention to clutch release arm & thrust bearing.

Removed release bearing and clutch lever shaft. Also removed clutch slave cylinder and brackets for overhaul and painting.


Bell housing cleaned down and oil seal removed.

Installed new oil seal and removed oilite bush for starter motor and replaced with new. Left this soaked in oil for 24 hours and it slid in okay.

Purchased new lever arm, left hand bush and grease seals. Right hand bush okay.

New shaft installed okay, left hand bush was a bit of a fiddle to get in right position. Lever was also difficult to fit due to being a tight fit on end of shaft. Once circlips fitted then installed clutch release bearing.

Removed front gearbox mounting and replaced bush.

[jeffj]

Now back to engine to fit rest of misc bits. Installed new engine mountings to brackets and fiited to engine.

Set tappets and timing and fitted new gaskets and rocker covers.
My previous experience of setting tappets was the rule of 9?
VW method seems very adhoc. Back of adjuster then screw in until touching valve then further two rotations and relock.
Sounds simple? Rocker tight on valve but you can push the rocker down on valve push rod and create gap? Assume the hydraulic tappet takes this up?

Distrbutor, oil pump, carb and misc pipe installed.


Exhausts, tinware fitted to underside. Had to carry out weld repair to left hand tinware due to rot.


New silencer installed. Had to make new plate straps for the silencer. Cut the ends of old straps and welded to new plates. Also had to carry out small repair to web of one of the pressed brackets.

Carb/manifold installed.

Engine now ready to install once lifted of engine stand.

[jeffj]

Big day for engine install. Sunday 6th Jan 2013.
Mark Foss volunteered to assist again.

Stared by removing engine from stand onto deck.
Fitted crankshaft oil seal, flywheel, clutch and cover plate.

Fitted starter motor in position and reconnected wiring.


Engine ready to slide under van.

Slid engine under van on old timber flooring and carpet.
Once under van lifted engine onto two trolley jacks and manoeurved into position. Set engine at correct height with Mark keeping it balanced level. Then just pushed straight onto the shaft and bell housing. How EASY was that. Mark did not believe me when I said its gone straight in. Fitted bolts and nuts to bell housing.

Installed tinware over exhaust silencer and jacked engine upto correct height and fitted bolts though cross member to chassis. Reightened gearbox mounting. ENGINE IN.


Overhead shot of engine.

Started fitting misc. pipework, electrical connections, alternator, oil filler neck etc.

Mark came in his van which gave us some reference for fitting of electrical connections and routing of wires in engine bay.

Had to now stop at this point as it was getting dark and still a lot of misc. items to fit before we can fire up. Will now leave until next weekend to finish off.

Outstanding works.
Install water bottles.
Fit water pipes.
Fit oil sensor wire.
Renew petrol pipes.
Fit clutch slave cylinder and bleed.
Fill with oil.
Fill with antifreeze.
Fire up.
Check with strobe light.

Many thanks to Mark for his help.

[sarran1955]

Hello,

Good work....

It goes so easily if you do one thing at a time!!

Small moan... your distributor vacuum hose looks past its best...

Don't forget that you will have to do a full valve re-time and cylinder head re-torque at 500 km.

Please make sure that you do the heads at (say) 18 and then 23 in 2 steps and go round with the torque wrench 3 times.

Timing valves is easy, set to TDC 1, do cylinder 1, turn engine 1/2 turn anti-clock wise, do 2, another 1/2 turn , do 3 and so on.

Do it twice


Hydraulic tappets, contact + 1 turn for now.

Then re tighten all the exhaust nuts

Nearly there...

Cordialement,




Hope you don't regret not changing the exhaust valves ...

[Mark Foss]

No problem with the help Jeff keeps me out of mischief! Just need to see it running now

[jeffj]

Spent this morning refitting all water hoses and topped up with water, changed all petrol pipes.

Spun engine over on starter with coil disconnected to get oil pressure. Connected coil and tried to fire up. Nothing.

Checked spark and okay.
Checked fuel and nothing through yet.

Connected temp supply up to carb and tried starting again. Fired up okay, had to turn off quickly as petrol starting coming through pump.

Connected fuel pump back up and fired up again and ran at tick over. Tapping noise from right hand bank but other wise running smoothly
Water leak started from overflow bottle as had connected bottom hose to block? Connected pipes up correctly and started again.

Ran engine to warm up a bit, tappets still noisy and exhaust smoking badly? Light grey coloured smoke. Its not burning oil as no smell.

Turned engine off to check oil and water levels.

Also bled new clutch master cylinder. Pedal travels to floor when bleeding but when nipple tightened up pedal will not travel all way to floor.

Started engine again to get it fully warmed up. Couple of water hoses to nip up.

Cannot get in gear? Rebled clutch but no better? Still the same? Will try in morning to crack the connection to the master cylinder as must be air trapped in system?
Got engine up to full temp and grey smoke still comimg from exhaust. Is this a symptom of a sticking tappet?

[tandemsandy]

I had the gearbox off to fit a new clutch just before christmas. I was surprised how long it took to bleed the clutch afterwards before I got pressure at the pedal. Am sure it'll be fine if you let it bleed for longer.

Rob

[jeffj]

Checked oil and water levels before start up. Bit of oil and about pint of water.

First two photos show smoke from tail pipe on start up.




These two photos show smoke from exhaust after about 2/3 minutes.




Engine ticks over fine although I still need to set with strobe light.

Looked at clutch again and bled slave with pressure bleeder and normal pump and nip method. No difference so still not able to drive vehicle.

Not sure if master cylinder may need resealing? You can select gears when engine not running? With engine running no strange noises when clutch depressed but will not go into gear.

Pedal is not travelling all the way to the floor when depressed but clutch slave is at its end of travel?

[kevtherev]

that's steam, condensation, it's cold.. and as water is a byproduct of combustion it condenses in the cold atmosphere, in this weather it will still be steaming for a long time too.

[sarran1955]

Hello,

I would expect the engine to be a bit smokey after a rebuild, and will need to run for about 2 hrs in easy bursts,
to bed the rings and so on in.

Clutch is either :need force bleeding, or.....

you couldn't have.....




put the driven plate in the wrong way round,( spigot faces you...)

Have fun..

Cordialement,

[jeffj]

Had my able assistant Mark with me when clutch plate installed and we double checked and fitted it correctly.

Ordered new clutch master cylinder today so will fit that and see if its helps with bleeding.

Sent home from work early today due to snow fall. Checked levels again after running yesterday and needed about inch of water adding.Then ran the engine again for approx 20 minutes. All okay.

[jeffj]

SNOW STOPS PLAY.



Checked water and oil levels again nothing needs to be added. Fired up engine and ran for further 20 minutes. Must have two hours running time now.

Just want to get clutch sorted now so I can drive it.

Tried to get my head underdash tonight to look at clutch master cylinder? Laid between seats and bent round gear lever but could not get my head past edge of dash.
This is not going to be the easiest place to get when you are 6`4" and 16 stone.

Going to leave until Friday now and see if I can get laid across the footwell from passenger side to reach cylinder.

[jeffj]

Fitted new clutch master cylinder and bled this morning.

Once you get in the right position it is fairly easy to access (laid across front footwell from passenger side). Was looking in the wrong place the other night as I was thinking it was up behind the dash.

It just drops below bottom of dash between brake and clutch levers.

Slight improvement but gears now grinding when attempting to put in gear?

Having to leave it now as snow has started again.

[jeffj]

Have removed thumbnails photos from early part of blog and replaced with bigger items. Hopefully pictures will be clearer now.

[Plasticman]

you sorted it yet? sounds much more like a mech problem than a hydraulic one,
know your village very well
mm