media goes big

[T-Boy]

Yeah man, I can help you out with it.


Sent from my campfire using smoke signals.

[dood786.]

Great progress so far

Pity about the hassles so far

[media]

thx man.
i will just at the hassles..

bump for day 12 and the first start!

[T-Boy]

thx man.
i will just at the hassles..

bump for day 12 and the first start!

Updates?

[media]

Had it running for a minute. Gave it a little gas and it hesitated a bit, gave it a little more and it bogged out.

Tomorrow I will start it up and let it sit for a bit. The battery needs a better charge. The trickle charger I have it on gets it enough for a couple of starts and that's it. Kind of limits the number of times I can restart it if it doesn't get charged up good.

Need to recheck vac lines. Need to figure out why it bogged out.

It just dawned on me... the 4bar fpr is still in there. Tune calls for 3bar. Bet it got too much gas. Need to dig out my old 3bar (if I can remember where it is..)


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[dosmas]

[Aonarch]

[T-Boy]

Had it running for a minute. Gave it a little gas and it hesitated a bit, gave it a little more and it bogged out.

Tomorrow I will start it up and let it sit for a bit. The battery needs a better charge. The trickle charger I have it on gets it enough for a couple of starts and that's it. Kind of limits the number of times I can restart it if it doesn't get charged up good.

Need to recheck vac lines. Need to figure out why it bogged out.

It just dawned on me... the 4bar fpr is still in there. Tune calls for 3bar. Bet it got too much gas. Need to dig out my old 3bar (if I can remember where it is..)


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That'll do it....

[media]

Starter is dead..

I got a few more starts out of it and then it gave up. Pulled it back off and bench tested, nothing..

So, that's next on the agenda...


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[T-Boy]

Starter is dead..

I got a few more starts out of it and then it gave up. Pulled it back off and bench tested, nothing..

So, that's next on the agenda...


Sent from my campfire using smoke signals.

If it's not one thing....it's another. LOL
I know the feeling bro. Just push start that biatch!

[media]

stepped away from this for a minute to get the jetta on the road, but back into it again. with a few more headaches. updates on page one. I will call it Day 13, although I haven't had a full day to devote in a while.

I hit a bit of a snag. Need to do some research as to what may be causing this problem. Open to suggestions.

[T-Boy]

Damn Jeff sucks to hear....need to figure this out!

[elRey]

[media]

Pulled the valve cover and soaked the cams and gears with some pb blaster. Shot some into the cylinders too. Letting it soak for the afternoon and I will see about it this evening.

That was quite a chore. I need to get an AGN cover just so I don't have to clock the turbo 45* to get the cover off.

I don't mind so much that it is giving me a hard time.. or having to fix/adjust whatever the problem is. I just wish I could figure out why it won't turn by hand, so I could get on with fixing/adjusting it.

Hope someone reads this and gets something out of it. I know it's nice to read about hurdles that other guys have run into and get the answers before I get to the problem.


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[TightDub]

[media]

I'm gonna bet on the head. Need to get those valve tools from you Tom, rebuild the AWW head and try that.

You got me thinking about sludge in the AEBs and I can't help but wonder if that has something to do with this. I put a 2' breaker on the crank and it doesn't want to budge. Hasn't even been started yet..

So next plan of action is to rebuild the AWW head, i know its good (minus the bent valves). Just need to decide on whether or not to port and polish to match the intake and exhaust of the AEB, or just keep it as is for now. Then rebuild the AEB with some good valves, springs, etc and put it back in at a later date.

Looks like tomorrow will be a mk2 maintenance day. T-belt, etc.



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::EDIT::

Nah. I think I just need to find an unmolested intake mani. Not worth my time to port this one. Rather get it on there temporary, and get the AEB up to par. Anyone have a mani they want to unload? (local preferred)

[T-Boy]

Jeff you're more then welcome to my tools. Also ask wren if he has an intake mani.

[media]

good call. i will shoot him a message.


Actually, upon further investigation.. Looking at the: Lisle 36200 Valve Keeper Remover and Installer

I need to measure the valves, but seems like it will work more quickly/easily than the compressor. It has two different sized tools. From their site: Quickly Removes and Installs Valve Keepers On Most Overhead Valve Engines With Valve Stems >From 4.5 to 7.5mm and 5/16" to 3/8"

Appreciate the offer to loan me yours though.

[T-Boy]

good call. i will shoot him a message.


Actually, upon further investigation.. Looking at the: Lisle 36200 Valve Keeper Remover and Installer

I need to measure the valves, but seems like it will work more quickly/easily than the compressor. It has two different sized tools. From their site: Quickly Removes and Installs Valve Keepers On Most Overhead Valve Engines With Valve Stems >From 4.5 to 7.5mm and 5/16" to 3/8"

Appreciate the offer to loan me yours though.

I looked at that, and it'll work great on the exhaust valves, but too big for the intakes.
Thinking about things, I forgot to ask you. You swapped the cams and stuf from your aww head to the AEB head, did you swap cam caps also?

[media]

woke up early this morning and have been researching this.
i was thinking the same thing. all of the videos that i have seen are with springs that are more visible. not so inset. stinks. that tool would be so easy.

looks like i may be able to remove them with just a magnet and socket though.

as for the caps, i didn't swap the cams or caps, just the t-belt gear, cam window/sensor on the intake and the VVT tensioner.

i remember that the head was difficult to turn from the beginning. i was rotating the cams to see how the valves worked before installing it. since this is my first time doing this, kind of just figured it was because of the fresh assembly lube, since it is kind of sticky.

Thinking back to the AWW head, when doing a T-belt I could easily turn the engine to TDC with the exhaust cam gear. It should not have been that hard to turn. hmm. well, the suspense is going to suck, but I need to get the belts done on the Jetta today first.

[T-Boy]

Well good luck, and let me know when you pull the head off.

[rodgertherabit]

Bummer about the Bearing.. Been there (January actually).

This is giving me motivation to drop the rods in my Donor block now

[T-Boy]

Jeff, looking over the pictures you took. I found something of interest, not sure if it would cause issues but.....







Why do I see one rod showing the tang, yet the other rods in the picture that I can see, seem to not have the tangs showing. This would mean you had one of the rods installed in a different orientation. I don't know how much that would play in to the issues you're having, but I'd have a second look at that.
If it were me I'd want every rod facing one direction.

[EURidahO]

I looked at that, and it'll work great on the exhaust valves, but too big for the intakes.
Thinking about things, I forgot to ask you. You swapped the cams and stuf from your aww head to the AEB head, did you swap cam caps also?

Aside from not fitting on the intake valves, this thing also fails to install keepers on our stuff. Only really works on single groove keepers and ours are 3 groove.

[media]

Bummer about the Bearing.. Been there (January actually).

This is giving me motivation to drop the rods in my Donor block now

Aside from not fitting on the intake valves, this thing also fails to install keepers on our stuff. Only really works on single groove keepers and ours are 3 groove.

thanks for the input.


I noticed that too Tom. At the time, didn't really think it should matter since they are all perfectly round. As long as the tangs are on the same side per pair, BUT while I am at it I should fix that.

Good eye.


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[T-Boy]

Tang should be on the intake side of the motor.

[media]

Thanks. Had no idea it mattered.


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[media]

Pulled it apart last night. Head seems fine, so I will keep it and just do the valves on the AWW so that I have it done. (thanks again for the extra valves and tools Tom!)

Found cyl 2 had the tangs on the exhaust side and 1,3,4 had tangs on the intake side. 3 was the one that burnt up, so I still think that it may not matter on a new set of internals, but I pulled them all out, corrected 2 and cleaned everything/re-lubed. Then put it all back in and still feel like the crank is too tight. 50ft/lbs on all bolts as per ARP instructions. So I am going to test a different tq wrench. Mine should be fine, but I don't know what else would cause the crank to be so tight.

As I am tqing each rod, it starts easy to turn and gradually gets harder. Makes sense, but when I get them all tq'd it feels too tight. Conversely, I don't want them to be too loose, so tomorrow I will try another wrench and see how it compares.

One other thought I had was that since the pump is in the way, I use an extension on cyl 1. Aaaand since I use it on one, and want consistency, I use it on all. I think the twist of the extension may be causing over tightening too.

Tomorrow I will pull the pump, try a different tq wrench and be sure that no extensions are used. :fingerscrossed:


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:EDIT:
Couldn't wait. Went out and retorqued while wife is getting ready to leave. Seems better. Still tight but maybe just because it's new? Will put it back together tomorrow.

[Shamrock]

when i installed my rods I had the pump and chain disconnected... I know it was easy to tighten them down and everything with the pump off and I did cylinders 2 and 3 first then turned it so so 1 and 4 crank was close to the "crank Journals?" 2 and 3 were close before I turned it.

[T-Boy]

Jeff did you re-plastic gauge all the bearings again just to be sure?
Oh and have fun with messing with the keepers! Lol

[media]

Daaamn. Well I figured it out.. When I was doing the initial assembly, I was soo sure that I had the parts all laid out in order that I didn't check the numbers on the caps to match the rods. I must have put the first one on correctly and then grabbed from the wrong side of my line of caps, because the other three were off.

I was replastogauging yet again. This morning it felt too tight again. So I pulled them apart and started noticing that yea they were in spec, but the readings were pretty far off from one another. The one that burnt up was the tightest of all. Swapped them to their proper partners. PERFECT FIT!

FINALLY!!! I think the best part is just that feeling of I FOUND IT! It would forever eat away at me if I would have fixed the problem accidentally and not known how I fixed it.


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[dood786.]

Sometimes you miss the small things

Well done on finding it

Epic build thread, hope it finishes off well

[T-Boy]

That's good to hear jeff!

[dosmas]

I think the best part is just that feeling of I FOUND IT! It would forever eat away at me if I would have fixed the problem accidentally and not known how I fixed it.

glad you found out. good to know theres build threads where they find the problem rather than throwing it at a shop in pieces.

[media]

drove around a bit last night on some back roads, seating the rings. smoking is subsiding, so it looks like it'll be good to go.

excited just to have it on the road.