VW 1.6 NA to Turbo swap! Questions and Progress.

[libbydiesel]

First over piston would be the first size over stock piston, so a 77mm piston because 0.50mm over size is the "first over" size piston.

The oversizes are:

1st=0.25mm
2nd=0.50mm
3rd=1.00mm

I don't know of anywhere that sells 1st oversize.  I have heard that the 1st oversize was reserved by VW for factory long blocks that needed some minor correction to the manufacturing/machining and were not typically available to the general public.  Because of this, many parts suppliers only show two oversizes and call the 0.5mm oversize the 'first oversize' and the 1.00mm oversize the 'second oversize'. 

[Tmarkle]

First over piston would be the first size over stock piston, so a 77mm piston because 0.50mm over size is the "first over" size piston.

The oversizes are:

1st=0.25mm
2nd=0.50mm
3rd=1.00mm

I don't know of anywhere that sells 1st oversize.  I have heard that the 1st oversize was reserved by VW for factory long blocks that needed some minor correction to the manufacturing/machining and were not typically available to the general public.  Because of this, many parts suppliers only show two oversizes and call the 0.5mm oversize the 'first oversize' and the 1.00mm oversize the 'second oversize'.

Huh weird. P.S. sorry if this becoming more of a project discussion that turbo swap discussion is annoying people. If a moderator can move this to a project category or something like that.


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[libbydiesel]

There's nothing wrong with this thread being where it is.  It's appropriate.

[Tmarkle]

Got the valves out. Forgot to get pictures. Tomorrow after work I will check the valve guide's
inside diameter.

Best way to remove the valve seals?

Are the valve spring exhaust/intake specific? I kept them separate just in case but I thought I better check.


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[Tmarkle]

So I checked the head for flatness tonight. I did not use a machinist straight edge, but a very expensive 6 foot one. No matter where I placed the straight edge across I couldn't get a 0.003" feeler gauge under it.


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[ORCoaster]

Doesn't sound like you have a warped head then.  A quick polish might be all you need.  Just to clean it up for the install.

[Tmarkle]

Doesn't sound like you have a warped head then.  A quick polish might be all you need.  Just to clean it up for the install.

That's what I was hoping to hear haha, the only thing I'm still stumped on is getting the old valve stem seals out. I should have just left them but I tried getting one out and pulled the spring and some rubber off so now I definitely need to get them out and replace them.


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[burn_your_money]

Not this exact one, but this style plier works great for valve stem seals.
https://www.amazon.com/Valve-Removal-Pliers-Serrated-Overhead/dp/B014OSYFG8

[ORCoaster]

AS long as you have replacements there is no reason to baby the seals when getting them off.

[Tmarkle]

AS long as you have replacements there is no reason to baby the seals when getting them off.

I have new ones. No problem there. Ordered a tool kit with a removal tool like above and a set of install tools.


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[Tmarkle]

So I dropped one of the cam followers on the ground... grrrrrrrr! Will I need to replace it or should it be ok? And will cam follower damage from the belt snap definitely be visible?


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[ORCoaster]

Lifters?  or that round can like thing that goes over the springs and has the spacer on top?  The Cam followers.  I am not following the wording you are using here. 

[Tmarkle]

Lifters?  or that round can like thing that goes over the springs and has the spacer on top?  The Cam followers.  I am not following the wording you are using here.

Oops sorry I'm used to pushrod engines. Yes I meant cam followers.


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[ORCoaster]

As long as you clean it up real good and get the grit off of it you should be fine.  I have one in my engine that actually has a bit of the lip that is on top of it that holds the shim in place.  The cam lobes don't get near it so it is not a problem.  I have replacements now but I really don't want to pull the cam just to replace that one piece.  It is working so why mess with it?

[Tmarkle]

As long as you clean it up real good and get the grit off of it you should be fine.  I have one in my engine that actually has a bit of the lip that is on top of it that holds the shim in place.  The cam lobes don't get near it so it is not a problem.  I have replacements now but I really don't want to pull the cam just to replace that one piece.  It is working so why mess with it?

By the way this is a hydro head so no shims. I'm not super familiar with the hydro system so I wasn't sure if there was a mechanism inside that could have been damaged by the fall or the belt failure.


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