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Author Subject: Engine overhaul!
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

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Post #126
MCH_GTi6 wrote:
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?


Worth checking for what?
Posted 3rd Dec 2009 at 13:34
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infosellerfsmail

Regular

Location: Hook

Registered: 18 Sep 2009

Posts: 127

Status: Offline
Post #127
Hi Deepak

Just wanna say how good this thread is mate definetly keep it going its great on how much details you give and the quality of picutres.

If people don't mind me saying your a credit to a forum like this!

Keep up the good posting!!

Cheers Josh
Posted 10th Dec 2009 at 16:18
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720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #128
Hello people,

First off thanks for the support tez and infosellerfsmail. There's plenty more to come as soon as I get the time to mess about with my own car and not others!

MCH_GTi6 I know all about the diagnosis you're telling me. I know a lot of people insist that the valves are bent and are difficult to detect but I want to make eleminate the lifters before anything else - as I strongly believe they are the cause. If this fails I'll contact my engineer and ask him to help me out.

Anyway, as soon as I do any more work I'll post up the pics and a write up.

________________________________________

Deepak Gohil


Posted 11th Dec 2009 at 00:23
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720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #129
Sorry about the delay on this people, I've just ordered a new hydraulic tappet and I'm waiting for it to arrive.

I'm planning to rebuild all the tappets and replace the one that looks overheated.

Hopefully, as long as time and other commitments permit I will have the head put back together on the weekend.

I also want to do some further tests on the valves - this will include a lot of measuring - and I'll post the results up when I can.

Hopefully you'll all stick with me, as I'm preparing quite an indepth analysis of why the the heads tap after a rebuild.

________________________________________

Deepak Gohil


Posted 14th Dec 2009 at 23:40
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720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

Posts: 1,069

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Post #130
Bloody hell I didn't half take my time with this! But I put the head back together today.

I actually replaced 2 inlet valves... I checked all the valves in a lathe and measured the run out on the face using a DTI gauge. I have results and will post them up soon along with lots of pictures.

Hopefully I'll have the car started tomorrow too.

I hope you guys are still interested...

________________________________________

Deepak Gohil


Posted 2nd Apr 2010 at 02:47
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i big al i

Senior User

Location: Arnside

Registered: 27 Jul 2007

Posts: 653

Status: Offline
Post #131
Just read the whole lot LOL
Brilliant thread mate keep it up Thumbs up

Alister

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Posted 4th Apr 2010 at 05:00
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720puggti

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Location: West London

Registered: 18 Jan 2009

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Post #132
Cheers Alister Wink

I actually have the enigne running now and the tapping noise has disappeared, but I will be keeping an eye on it to make sure it everything is good before I put everything back in place permanently.

I've got some pictures and measuring results too...

________________________________________

Deepak Gohil


Posted 6th Apr 2010 at 02:10
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jose

Senior User

Location: W.London

Registered: 05 Oct 2008

Posts: 675

Status: Offline
Post #133
in, out, in out, shake it all about Wink

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Posted 6th Apr 2010 at 02:22
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720puggti

Seasoned Pro

Location: West London

Registered: 18 Jan 2009

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Post #134
When I mesaured the valves I put them in the chuck of a lathe and torqued them to 48lbs inches. They were each mounted at the same distance on the stem too to make sure readings were fair and accurate. The DTI measurements were taken on the valves face as this is where any distortion would be amplified.



As you can see valves 3 and 4 showed the most run out. This is totally undetectable be eye, be it on a flat surface or even using straight edges.

________________________________________

Deepak Gohil


Posted 6th Apr 2010 at 02:24
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720puggti

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Location: West London

Registered: 18 Jan 2009

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Post #135
Jose, come on man, this is all gonna be done properly Wink

________________________________________

Deepak Gohil


Posted 6th Apr 2010 at 02:24
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720puggti

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Location: West London

Registered: 18 Jan 2009

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Post #136
Anyway, I lapped the valves back in, but this time I used quality grinding paste Chemico, Last time I used halfords own. I'm sure there isn't that great a difference but I'd rather be sure.



Original valves were used as I've heard that pattern ones can fall apart. In fact everything that is in the engine is original, for peace of mind.

I don't know what's happened to the pictures, but I took all the tappets apart, so the bucket, piston, check valve and spring all came aprt for the 16 of them. I soaked them all and rebuilt them using clean oil - something I should have done in the first place but didn't realise. I also cleaned their faces up using wet and dry paper giving them a nice grey look instead of the usual shiny one. You can just see the faces in this picture

________________________________________

Deepak Gohil


Posted 6th Apr 2010 at 02:37
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720puggti

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Location: West London

Registered: 18 Jan 2009

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Post #137
After calling Carl AKA Mechanical Repairs, he suggested I built the head back up off the cylinder block unlike last time where I built it on the cylinder block. This just meant I saw exactly what positions the valves are in and I can make sure they don't interfere when I time the head up.



(Sorry about the Quality it was taken on a phone!)

________________________________________

Deepak Gohil


Posted 6th Apr 2010 at 02:41
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720puggti

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Location: West London

Registered: 18 Jan 2009

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Post #138
When I actually put the engine back together and in the car I only put on the essentials to keep it running. No clutch, PAS Pipes A/C pipes, cables, unnecssary brackets, subframe, d/shafts or covers. Only the plumbing was connected.

Anyway, I'm gonna test it for a while longer making sure no more noises develop and then hoist it back out, tidy the bay properly and clean the engine a bit more, out it back in place and replace a few other things including:

Lower arms
Gear Linkages
Timing Belt (The one on there is new, but it has been exposed to oil and other fluids)

Hopefully when the engine and its bay are finished I can turn my attention to the body...

________________________________________

Deepak Gohil


Posted 6th Apr 2010 at 02:47
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spike_uk06

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Location: Billingshurst

Registered: 03 Aug 2006

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Post #139
Keep it up buddy you will have one mint engine and car once your finished! Thumbs up

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Posted 6th Apr 2010 at 04:23
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rallyestyle

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Location: London

Registered: 23 Jul 2003

Posts: 14,990

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Post #140
Great work Thumbs up

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Just Drive It
Posted 6th Apr 2010 at 17:37
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720puggti

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Location: West London

Registered: 18 Jan 2009

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Post #141
Thanks for the nice comments guys Smile

The engine is running nice and smooth and there are no strange noises. Phew!

Just need to find more time and money to get this all finished...

________________________________________

Deepak Gohil


Posted 14th Apr 2010 at 02:07
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china_306 Banned!

Location: Stoke

Registered: 25 Nov 2009

Posts: 129

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Post #142
Congratulations mate! Smile really good read, i don't have a gti6 but very glad that you lookafter yours Smile
Posted 14th Apr 2010 at 02:46
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kit

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Registered: 22 Jan 2009

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Post #143
I've only just come across this thread. Read it all so far, great read and good work Deepak Thumbs up

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Posted 6th May 2010 at 03:38
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monkgti

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Location: New Ross

Registered: 31 Jul 2009

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Post #144
excellent work and alot of time and effort put into everything Yes also a very good and interesting read Wink

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IF YOU CAN READ THIS IM STILL IN 5TH!!!
Posted 6th May 2010 at 18:02
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720puggti

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Registered: 18 Jan 2009

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Post #145
Thanks once again for the nice comments guys Smile

I'm actually in the middle of exams at the moment so this really is my last priority. Got lots of plans though which I'll update you all on once I've got the time!

________________________________________

Deepak Gohil


Posted 8th May 2010 at 05:45
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jonnie205

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Location: Bicester

Registered: 10 Apr 2005

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Post #146
so you started the engine with no gearbox on?
Posted 9th May 2010 at 00:16
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720puggti

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Post #147
^^^ I did fit the gearbox, I just didn't fit the clutch. I fitted back the bear minimum to get the engine running basically. I didn't even fit the subframe Smile

________________________________________

Deepak Gohil


Posted 15th May 2010 at 22:17
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720puggti

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Location: West London

Registered: 18 Jan 2009

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Post #148
Hello to anybody that is still interested in this thread! I haven't really posted anything on the forum recently, let alone this thread!

Anyway, usual stuff; I've been busy due to exams! However, in recent weeks I have made a lot of progress.

I managed to respray the whole engine bay! Which I will be posting photos of. I have also got the engine back in and am ready to start building it all back up!

If anyone can be bothered to stick with this I'll be posting photos later tonight along with words about how I got on.

Cheers all!

________________________________________

Deepak Gohil


Posted 28th Nov 2010 at 21:24
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welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

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Post #149
hello! Wave

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Posted 28th Nov 2010 at 21:27
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cwspellowe

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Registered: 19 Jul 2009

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Post #150
Excellent, love to see how it turns out Smile

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Bye bye Sundance Kid Sad
Posted 28th Nov 2010 at 21:33
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