please help

[billy739]

if the van has not been run for a while you may find the compressions uneven between cylinders due to dry cylinders, valves not seating (surface rust if in damp conditions) ect ect.

turning it over/running it may sort these out!

the head seals will come in a full engine gasket set , there are a few different types so look at your old ones.
i would have no problem nuying a beetle/baywindow 1.6 full gasket set as basically this is the engione you have . from memory a full gasket set is less than £5 (or used to be)

if you have the head off, you may as well remove the other side.

if there is no excessive play in the crank bearingd( up/down , left/right , forward/back)
then you should replace as a minimum bigend bearings, piston rings , 4 exhaust valves. this should then see you good for a few miles!

[camper]

From memory i think you can lap the heads to the cylinders with grinding paste to get a good seal.A did some work on a 2ltr cu engine and replaced the sealing rings but they came only supplied with a full engine gasket set.I asked for advice about this on the 80/90 forums .Replies said cylinder heads can be lightly ground in to the cylinders using grinding paste.Prehaps some one can clarify this if i am correct or wrong.

[billy739]

yes this is how the heads/barrels originally sealed on bays and beetles, no gaskets- just ground in , just like a valve to its seat.

not normally needed tho if your fitting head rings(gaskets) but you can give them a spin just to check and make sure all is good!

i think the shims are there to lower the compression more than seal the heads

[craigfev]

right well today i've tried to get some head rings and failed miserably im off work tomorow so i think im goin to try GSF fo a full gasket st and if that fails tthen ill lap them in slightly upon removal of the cylinders i found this engine has a full set of new pistons and rings whch i thought was strange even the spark plugs have not been fired this may be because there where no HT leads with it any way project rebuild tomorow and i'll let you no how i get on many thanks for all the imput
can any1 tell me what to set the tappets to mr haynes sez just back them off completely then screw them in 2 turns but i find that hard to swolow

[camper]

I dont think the 1.6 cc aircool engine has hydralic tappets the haynes manual refers to two turns for hydra setting tappets for 2ltr cu engines & .I carnt recall how many thou the exhaust & inlet are set to on the 1.6 cc engine but some one will come along and advice you.Lapping in the cylinder to the heads works well .

[craigfev]

hi its me again got no spark comin from the distributer any ideas?
the loom that goes to it has 3 wires leading to it and a 4th comin off the loom that i cant find where it goes if haynes is right then its an earth that goes near the dizzy but where i dont know?

[billy739]

the earth sopmetimes clips onto the dizy body , theres a terminal usually opposite side to the electrical connection

or it goes to the engine near the base of the dizzy , on a bolt thats on the engine with a terminal on it.

just clamp it temporaraly to the engine , see if that works!

[craigfev]

tried clamping it and rubbing round varios shiney points on the block still getting nothing from the dizzy i'm thinking about gettin a new 1 but dont want to waste me money if its not that is at fault.
should i reaplce the 2 black boxs on the left hand side of the engine bay if so any ideas where to find some new 1s?

[kevtherev]

so you've tried the coil (king lead) for a spark on no joy then?

[craigfev]

ive put a plug and lead comin off the middle of the cap

[kevtherev]

and...?

try offering the lead to a good earth point... no plug.. just the lead, does it spark like a good un?

[billy739]

the black box with 2 plugs at the bottom , unplug the 2 plugs and connect them together. try your tests again

[craigfev]

woop woop it now runs the next things i need help with theres a vacume port comin from the nearside inlet manifold when my finger is covering it it runs sweet but i cantdrive it with my finger over it and cant find any pipes or connections for it and thres nothin in the haynes?
on my carb theres a return hole which pisses out fuel when running (DANGER) cant find anywhere for that either please help
also i appear to be missing an alternator mounting bracket and loom for the alternator any imput is greatly appreciated thanks

[VWCamperfan]

What size is the vaccuum port (diameter)?
If it's just a fuel return outlet on the carb then this can be blanked off.
May need piccys for the rest!

[craigfev]

about 10mm dia
what can i blank that return off with without causin damage
any ideas as to where i can get some new tin ware only mine has seen better days?