displaying posts 101 to 125 of 170

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Author Subject: Engine overhaul!
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

Status: Offline

Post #101
cheers greenbelt. i didn't run it for long, not for much longer than that video really.

________________________________________

Deepak Gohil


Posted 28th Jun 2009 at 03:36
paul_13

Senior User

Location: Reading

Registered: 10 Dec 2008

Posts: 693

Status: Offline

Post #102
Good to hear it started, I can't wait for my 6 conversion to start.

Bloody wiring woes Angry

________________________________________

205 GTI6- Rebuilt engine, lightened flywheel, lightened pulley, 307 hdi brakes, Koni struts on gravel spec springs, 22mm TB's, 24mm ARB, Roll cage, Citreon ZX rear dampers, SL434's, Xsara box, Quickrack, Pipercross enclosed induction kit. Smile

Private work, not a prob Smile
Posted 28th Jun 2009 at 05:57
gocart man

Junior User

Location: east halton

Registered: 09 Jan 2008

Posts: 87

Status: Offline

Post #103
Great work!!
Did a complete engine swop a couple of years ago when i bent 2 con rods. Brings back memories. Sold it to my father in law. Just bought another 6, this had the same issue but was cheap for a V reg. Currently just putting it back togrther now. Left my engine in and have removed head and sump, just got head to put on and all the rest.

Good threads, nice to see work completed correctly!!!
Posted 7th Jul 2009 at 20:20
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #104
^^^ cheers mate. but i have some bad news!!

unfortunately i made an error in re-assembling the engine... although it runs it is making the dreaded tapping noise! so i'm going to whip it off and take out the valves to check what's gone wrong.

i gave Carl (aka mechanical reapirs) a call and he told me it was probably my method of re-assembly. i had no idea that the tolerance was so close.

oh well, i live and i learn... hopefully it'll be running sweet this time round.

________________________________________

Deepak Gohil


Posted 8th Jul 2009 at 19:45
jose

Senior User

Location: W.London

Registered: 05 Oct 2008

Posts: 675

Status: Offline

Post #105
720puggti wrote:
^^^ i drove past the hospital today... i didn't see your car there. perhaps next time - i'll keep an eye out Wink


Thats because im living on Oxford atm, will be back this weekend so if ya need a hand give me a shout

________________________________________

Nile Blue GTi6

Alpine White 205 GTi 1.9 - Project

Air Con Pipes Thread.......

Machine Polishing - Paint Correction - Swirl Removal in West London - PM for details
Posted 9th Jul 2009 at 01:06
sport1901966

Senior User

Location: Hertfordshire/Epsom

Registered: 17 Aug 2006

Posts: 687

Status: Offline

Post #106
720puggti wrote:
^^^ cheers mate. but i have some bad news!!

unfortunately i made an error in re-assembling the engine... although it runs it is making the dreaded tapping noise! so i'm going to whip it off and take out the valves to check what's gone wrong.

i gave Carl (aka mechanical reapirs) a call and he told me it was probably my method of re-assembly. i had no idea that the tolerance was so close.

oh well, i live and i learn... hopefully it'll be running sweet this time round.


Out of interest what was the error?
Posted 23rd Jul 2009 at 22:24
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #107
^^ i don't know. initially my thoughts were bent valves. but they all seem straight.

the heads still in bits, as i'm having work done to my garage.

i'm gonna lap the valves in again and carry out a leak test to see if the valves are set in position properley.

i'll update the thread as soon as i can though, i hope people find my work helpful and interesting.

________________________________________

Deepak Gohil


Posted 23rd Jul 2009 at 22:30
dan gti-6

Regular

Location: Winchester

Registered: 26 Jan 2008

Posts: 112

Status: Offline

Post #108
720puggti wrote:
^^ i don't know. initially my thoughts were bent valves. but they all seem straight.

the heads still in bits, as i'm having work done to my garage.

i'm gonna lap the valves in again and carry out a leak test to see if the valves are set in position properley.

i'll update the thread as soon as i can though, i hope people find my work helpful and interesting.


Trust me you wont see the bent valves by eye, the valves will also seat and hold vacuum even when they are quite seriously bent, this is also the reason they run fine as tappers.
Posted 23rd Jul 2009 at 22:52
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #109
What was the outcome in this in the end?

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 25th Sep 2009 at 16:47
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #110
nothing so far. the head is still in pieces in the garage. although i'm pretty certain it's not the valves that are causing the tapping.
i have a strong suspicion that it's actually the hydralic lifters that have failed.
i didn't really clean them out properley. so i'm gonna physically take them apart and clean and rebuild them when i get the time. which won't be for a while yet, cos i have loads on plate at the moment.

but when i do get round to it all, i'll upload the photos and let eveyone know how it all goes.

________________________________________

Deepak Gohil


Posted 25th Sep 2009 at 21:20
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #111
It's not something silly like a loose spark plug is it? I had that once and it gave me the fear until it was discovered.

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 25th Sep 2009 at 21:29
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

Status: Offline

Post #112
i wish it was the spark plugs man! it definitely isn't them.

from inspection and using my own knowledge as well as 2 other techs i know, we're certain it isn't the valves.

keep an eye on this though, cos i will be updating, and i will be letting people know what went wrong, and perhaps hw they can avoid it and/or fix it.

________________________________________

Deepak Gohil


Posted 26th Sep 2009 at 22:45
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

Status: Offline

Post #113
Right People! Keep an eye out as this show is gonna be back on the road in a couple of days! Hopefully Thursday Big grin

You'll all also see the reason for why it's taken so long too...

________________________________________

Deepak Gohil


Posted 25th Nov 2009 at 03:07
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

Status: Offline

Post #114
720puggti wrote:

You'll all also see the reason for why it's taken so long too...


Dropped a screwdriver in the cylinder? Whistle
Posted 25th Nov 2009 at 13:38
rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,988

Status: Offline

Post #115
fletch wrote:
720puggti wrote:

You'll all also see the reason for why it's taken so long too...


Dropped a screwdriver in the cylinder? Whistle


LOL Hopefully more performance than accident based Unsure

________________________________________

Just Drive It
Posted 25th Nov 2009 at 14:26
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #116
Hi guys,

I know this is a bit later than I said it would be but I've been really busy! Anyway the main reason why this project has taken so long is because my garage was broken into along with two of the family cars.

So we thought it'd be a good idea to extend the garage to get more cars in...





They're not the best pics, but I couldn't get everything to fit in one shot!

It's a 4 car garage now, but half of it is my workshop! Big grin

________________________________________

Deepak Gohil


Posted 1st Dec 2009 at 03:10
jose

Senior User

Location: W.London

Registered: 05 Oct 2008

Posts: 675

Status: Offline

Post #117
looks really nice mate, would love a place like that to work on my cars, just needs a 2 post lift! Big grin

________________________________________

Nile Blue GTi6

Alpine White 205 GTi 1.9 - Project

Air Con Pipes Thread.......

Machine Polishing - Paint Correction - Swirl Removal in West London - PM for details
Posted 1st Dec 2009 at 03:17
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #118
Back to the head and the tapping now...

Basically when I started the car after re-building everything it started to tap. Dreading the worst, and being informed by members on this forum, I thought i must have bent a valve. So carried out some inspections and this is what i found...

What I did first was got a flat surface with a square in one corner (in this case a anti-glare screen). I then lined up the inlet and exhaust valves seperately to see if there were any obviously bent valves...

These are the inlet ones.






Visually they all seemed straight, but as a further check i got a rule and held it to the valves, sure enough all the valves touched at the same time.



These tests confirmed to me that I had not bent a valve.

I also got the same results with the exhaust valves.

________________________________________

Deepak Gohil


Posted 1st Dec 2009 at 03:36
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #119
So after this I cleaned the valves in the pillar drill with some scotchbright.



________________________________________

Deepak Gohil


Posted 1st Dec 2009 at 03:24
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

Status: Offline

Post #120
I then set up to re-lap the valves and clean the springs and collets etc...





________________________________________

Deepak Gohil


Posted 1st Dec 2009 at 03:25
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #121
So as for the tapping, my attention turned to the hydraulic lifters... all the lifters in the engine are the original ones except for one. I had to replace it as one of the originals had dropped.

Anyway, as I began to clean the lifters, I noticed that one of them was an odd colour...



Instead of being shiny like the others it looked like it had been overheating. Whether this was the new one I put in, I don't know, but I am almost certain that this is what was causing the tapping. It looks like I'm gonna have to buy another one!

This is one of the "good" ones...

________________________________________

Deepak Gohil


Posted 1st Dec 2009 at 03:31
720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

Status: Offline

Post #122
Anyway that's it for now, I'll be buidling the head back up on Wednesday... I think. More pics then!

________________________________________

Deepak Gohil


Posted 1st Dec 2009 at 03:32
tez_306

Junior User

Location: Australia

Registered: 16 Sep 2009

Posts: 68

Status: Offline

Post #123
Awesome thread, good luck with it all
Posted 2nd Dec 2009 at 14:30
stebro-gti-6

Newbie

Location: fareham

Registered: 16 Oct 2009

Posts: 38

Status: Offline

Post #124
The hydraulic lifters should be De pressurized before they are put back in the head, then you have to turn over the engine without starting it to get the oil pressure up .
Then you can start the engine, it will tap for a min or two but once the oil pressure is all up they should go quiet

________________________________________

China Blue on Black Clones
Posted 2nd Dec 2009 at 17:52
MCH_GTi6

formerly mch

Location: Hayle

Registered: 09 Sep 2005

Posts: 2,456

Status: Offline

Post #125
I dont know if anyone that has more knowledge than me can shed further light on this but,

I have 2 valves in my shed which I know are bent but by eye they look fine...
Was told they didnt "cut" perfect first time meaning they are bent - this was when I had a tapping head re-built
(only these 2 replaced and head never tapped since)

So worth checking with a machine/engine shop?

________________________________________

Team Moonstone´┐Ż Ph3 GTI6
Team Rallye
Posted 3rd Dec 2009 at 00:15

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