Need help, my rabbit is dying

[Baron VonZeppelin]

Speak up folks!!!  It's 3am and I'm outta cigars!!!

Don't roll them so fat and your bag will last longer   

[Rabbit TD]

wow lotta information, good stuff, I have one "leaky injector"so good idea to relace them.  They appear as if they have never been relaced 205,209 on the ODO and I still haven't tracked down the original owners, o find out maintenance history, which would help.  Head studs, from ARP I imagine, dimensions mentioned, I can check the block and head for warping etc. Have one of those straight ege thingy's that machinists use and a flashlight to check for dimples etc.  I want to avoid the machinist at all costs because there is no quality machining here in the desert anymore, and The only guy around's work is questionable and exspensive at best.   I can clean the valves and determining whether they are good or not is pretty easy I know a guy with a valve grinder and can do 3-angle jobs on my own.  I can alo port the head "although veeery time consuming" I have done it before and can do it again, polish the exhaust, What I really need is a Bentley, all of the dissasembly, reassembly ino clearances, head stud torque specs etc.  Is there anyone that has a spare?  I promise I'll give it back "with only a few greasy fingerprints" JK.

Thanks soo much you guys,

Kevin

Seriously before you buy anything get another book, there is no end to the problems on these creatures till you have basicly rebuilt the whole car.  Actualy probably rebuilt twice, by then we know what we didn't do right the first time.  But none of us will ever admit that publicly will we, Can I get an AHMEN   P.S., I have got 2 Master kits and lot sof other parts from Parts Place and have no complaints with their parts.  I have seen a change in their style since their change in ownership but they are still very good and you can talk to somebody on the phone who has more knowledge about VW's other than where they parked theirs at when they got to work like some places are.  Things are changing everywhere and pretty fast too but I think they are a still a very good place and their shipping is good too.

[maxfax]

Actualy probably rebuilt twice, by then we know what we didn't do right the first time.  But none of us will ever admit that publicly will we, Can I get an AHMEN  

I don;t know what you're talking about....      Now excuse while I go work on assembling my second engine...

[NintendoKD]

I realize that head stud specs aren't in a bentley bro, but they have to be somewhere on the forum as I really want to do this right.  I you talk to anyone I always measure twice before I cut, and If I cut it I do it really well or not at all.

[maxfax]

This was debated once upon a time..   The VW specs for 11mm bolts seem kind of low, I debate if that wasn;t because they knew the block would take no more..   I think the measuremant for the 12mm stretch bolts used on later diesels ends up to being something around 103 ft/lb...


Personally, I use the ARP specs, no problems yet.. At least with that particular aspect..  The uber fussey machinists at the machine shop concur that the arp spec is ideal for this setup..  Others prefer to torque them up to between 90 and 100 ft/lbs..  I guess if you happen to have a head that isn't quite flat the extra torque may make up for it... I've pulled that particular number myself on other engines...

[NintendoKD]

what head gasket should I use? three notch? lower notches means higher comp. no's right?  there is another post for the crank that I want to buy good idea? not sure on that on either.  Are there any special tools necessary for this build?  I don't want to have to do it twice, that's why I'm here, I want to avoid all of the mistakes that others have made.  I try to live vicariously.

[NintendoKD]

I am rebuilding everything, already decided.  I am rebuilding everything, save the fuel pump.  Replacing the oil pump, water pump, bearings, rings, and all of the seals and installing head studs.  Any other suggestions for trouble free, maintenance free..... er as little maintennce as possible, longevity operation are greatly appreciated.  Thanks, guys.

Kevin

[Rabbit on Roids]

Hey kev, take your 1.5, get a TD block, and throw the 1.5 roataing assembly in it. you willl need to get 1.5 pistons and notch them tho. its a pretty easy swap, then you have the beauty of a tough block, and the revs/powerband of a 1.5.

[NintendoKD]

anyone got one they can give me the idea is cheap here folks, reason being that the wife is already having a coniption over all of this I'l post up some pics, oh and I'll need someone to walk me through all of this like should I keep the cyl head as well? etc.  I don't want to go turbo for simplicity and price but hey if someone is feeling generous I told her I would get it running an then that's it, no modding, etc. so if she's got any inkling that I'm going somewhere crazy with this she will go crazy too and probably move back in with her parents in Japan and take my two year old with her  
oh and I don't know if I mentioned before but I live far away from a good boneyard with vw diesels and don't have a means to truck one out here even if I did.

[NintendoKD]

[NintendoKD]

I know what you all are thinking just how did he get the intake and full exhaust mani./downpipe off together while the fuel pump is still attatched?  Very carefully gentlemen, very carefully.

Ok, next are the other pics I took

[NintendoKD]

[NintendoKD]

looks like valve slap, bad rings??? should I get oversized rings to compensate for the old block walls.  I understand that the 1.5 blocks crack, however, I don't exactly see anyone giving one up and I don't have the cash to buy one and the rebuild kit, so I wll just rebuild this one RIGHT, THE FIRST TIME!  I will no doubt need everyones help, and preventative measures for this to go smoothly.  I think I should start a build thread just for this. but everything else is already here so I think I'll stay.  I want the most reliable best performance for the buck, without going turbo here so any and all input is welcomed.  Thanks so far everyone.

Kevin

[Rabbit on Roids]

those are really crappy pics, i cant even really tell what im looking at, besides a greacy 1.5. cant really assess damage from them. and the pistons are at the bottom of the bores too, so that didnt help much either.

[NintendoKD]

sorry the camera wouldn't focus properly, I'll rotate the rotting assy, and take some more pics tomorrow.  I'll also get the no's from the head and block to compare.  As far as I can tel this thing has never seen a machinista and those are the original internals, yes, original.  250,000 mi. and still original it was about her time I know some live longer, but I need something reliable and I can't very well shrug my problems off on someone else "that's how this all got started"  Do you notice the cracks in the cylinder head between the vave seats?  is that normal? I know that diesels are different but that looks bad

thanks,

Kevin

"fate rarely calls upon us at a time of our choosing"

The last prime