Happy days

[meggles]

I had it running a few weeks and immediately before doing the tubes. Was going to have a quick look at it last night but had a 200 mile drive at work so not a chance!

[meggles]

Thanks for the help chaps. Just finished looking at the van. Looks like I didn't take enough care ensuring some of push rods were correctly located. In fact it seems over half had slipped out of 'cup' in hydraulic tappet. Not finished it yet because of bad light, aching back and flat battery!!!! Never mind, all looking better now. Definitely got compression! btw, is there a way to make sure the push rods do not fall out of position whilst refitting the rocker shaft?

[itchyfeet]

btw, is there a way to make sure the push rods do not fall out of position whilst refitting the rocker shaft?

Yes just turn the van on it's side and gravity keep them in place

[meggles]

btw, is there a way to make sure the push rods do not fall out of position whilst refitting the rocker shaft?

Yes just turn the van on it's side and gravity keep them in place

Thanks for that, I'll try it. Which side is best?

[itchyfeet]

Depends on which side you are doing, the problem was so well known to VW mechanics they even made a special tool for it No. VW654

I don't think you can buy them any more.

[itchyfeet]

Seriously, I'm doing 3 and 4 again this morning because one tappet is a bit noisy so I took this pic to show how to tell.

[meggles]

It's OK knowing, it's doing something about it that's the less easy bit. Think I've nearly cracked it now. Plenty of compression but won't start. Need to get some oil for car now so slight break in the proceedings..... again! btw, thanks for pic.

[itchyfeet]

slacken screws right off also loosen shaft slightly until you can feel the rod is no longer pinched
then get a screwdriver between rod and head from underneath and lever a bit
it will pop into seat

just spent an hour or more get one in one pops out its fiddly

[itchyfeet]

and it won't have compression for an hour or two
when you release preload tappets suck in oil
when you reset preload they have to leak down again

Something else I notice today, can't remove a pushrod from No 3 on a late van, didn't try 4 maybe the same.

[meggles]

It lives!!! When I finally got back onto it, and after battery had been charged again(!!) and I had fitted a set of disc pads to the car. I double checked all of the area I'd been working in and found that I had carelessly pulled a lead off the coil doh!! Anyway, it started, albeit it very lumpily (is there such a word?). Not too tappety though Up to now there is zero oil leak Not quite as lumpy after a while but I do need to get some new plugs in it. I need to get rocker covers off tomorrow to see if there's any oil in them. Just being ultra cautious I know. One thing I'm not sure about though. Let's say I had screwed one of the tappet adjuster screws in one and a half turns and it should have been two turns, or vice versa. Do I need to re adjust them if there's no noise or lumpy running? Or will the hydraulic tappet 'compensate'?
btw, I had to bend the tinware slightly to remove a push rod.
I've quite enjoyed this challenge, or rather succeeding in the challenge. Struggling a bit with aching in chest now though, hoping just a bit of muscular discomfort, I'm sure it is. (Says he with firmly crossed fingers). Thanks a million for all your input Itchy. Must get you a pint or two sometime.

[ajsimmo]

General consensus is that 1.5 turns in is optimal, and it works for me. If you've got one noisy tappet (perhaps worn a notch internally) you can adjust it 1/4 or 1/2 turn in to see if it will quieten down at the new setting.
If you want to start an engine immediately after setting up, you can set no.1 & 3 valves at just touching, and 2 & 4 at 1.5 turns as usual. It will have compression on at least 2 cylinders and start immediately. Run until 2&4 are bled and running on all 4, then adjust 1&3 to the same 1.5 turns. Restart and run til smooth.

[itchyfeet]

As said meggles 1.5 turns or 2 turns will be fine.
1.5 is what Ratwell says, 2 is what VW says.
You can run it on one turn but it will likely be noisy.

the lumpyness initially is because one or more cylinders doesn't have great compression, it should settle down when oil heated up and the tappets pump up or bleed down as required.

Now go and gove it a good run

[meggles]

Doesn't sound too bad I suppose. Thanks for the help folks. Just need to get it tested now.