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    Thread: my 16v rebuild thread

    1. Member
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      08-28-2020 01:59 PM #901
      Parts are starting to arrive.
      New sticks.

      New pistons

      They are only a tad lighter than the aba ones


      New lifters
      They are the new revision of the tdi lifters and I was worried that they were a bit heavier that the old tdi lifers I had



      But I then pulled out one on the stock ones I had kicking around and ......... well still way less

      Also got a big pile of gaskets and seals

      New valve springs went into the head. After a little reading and talking with Colin at tt. Figured I would replace them just in case. I may have not been using the proper spring for the amount of lift the 288 cam had. Also apparently the high rev springs deteriorate with higher mileage. Better safe than sorry.
      The head is back from the head dr. A fresh valve job a real good cleaning new seals and fresh surfaces. Iím glad nothing was to messed up with it.





      They are currently working the new block and crank and donít expect any surprises.
      Once I get word on the crank I can order up bearings. I still have a few other odds and ends to collect. And a few other parts still en route.
      Last edited by vwjunkie42; 08-31-2020 at 06:23 PM.

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    3. Member
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      08-28-2020 02:18 PM #902
      Just realized I never posted finished bicycle pics








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    4. Member nOrcAL7's Avatar
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      08-28-2020 03:35 PM #903
      As always, awesome work.
      formerly known as "H20driven"

    5. Member
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      08-28-2020 09:33 PM #904
      Wow super nice! I canít wait to see this motor come together


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    6. Member
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      08-31-2020 06:21 PM #905
      Rods!!!!

      Also just a tad bit lighter then the stock od1 aba forged rods.



      Cleaned the work bench and flipped the top boards


      The pile of parts is growing

      Head is painted as is the new water pump




      Here is a pic of a part number just in case I need to find it later. Lol



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    7. Member
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      08-31-2020 09:24 PM #906
      Oh wow. This is gonna be money


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    8. Member
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      09-07-2020 11:50 PM #907
      Got a whole bunch done this weekend.
      Picked up the block from the machine shop.

      Got pretty much everything I was waiting for in the way of parts.

      Saturday morning got the bottom end all assembled.
      Checked to make sure everything was balanced

      Thankful when I built it the first time I spent the extra money on nice hardware.

      Crank in and mains torqued

      Pistons assembled and installed


      Saturday got the head all bolted down. Again glad to have arp studs

      I did take some time to modify the inner timing cover.
      I was able to get ahold of both the outer abf timing covers.

      But not the inner so I needed to modify the 9a one I had.
      Ended up trimming it where the lower bolts to the block

      I then made an opening in the inner to except the D shaped tab.


      Pretty happy with the results. It fits nice an snug



      Then got the head bolted down and torqued

      And finally test fit the modded covers.


      This morning got the head all assembled.
      New lifers in


      New cams installed

      got everything all timed with the Kent abf belt

      Then tossed the covers on



      I still have to get a few things. Like a valve cover gasket before I can flip it over and toss the pan on. I have a couple of sensors I need to get. Machine shop broke the coolant temp sensor. And I need to toss a crank position sensor to plug the hole. Opting not to block it with a freeze plug because I like the idea of having the option to go distributorless at some point down the road.


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      Last edited by vwjunkie42; 09-14-2020 at 12:40 AM.

    9. Member
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      09-08-2020 08:03 AM #908
      Very nice work, as always.

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    10. Member
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      09-08-2020 09:26 AM #909
      Wow this is looking great!

      What did you have the shop do to the block? Just clean it up?


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    11. Member
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      09-08-2020 05:08 PM #910
      Quote Originally Posted by ArclitGold View Post
      Wow this is looking great!

      What did you have the shop do to the block? Just clean it up?


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      Hot tanked and cleaned
      Pressure tested
      Fresh bore +.020
      Resurfaced the deck
      New intermediate shaft bearings


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    12. Member
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      09-08-2020 09:56 PM #911
      Awesome. Mind sharing what that runs? I need to do mine but I donít have any frame of reference for what it should cost.


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    13. Member
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      09-08-2020 10:22 PM #912
      Quote Originally Posted by ArclitGold View Post
      Awesome. Mind sharing what that runs? I need to do mine but I donít have any frame of reference for what it should cost.


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      Just under 400 for block work and measuring and polishing the crank


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    14. Member
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      09-10-2020 09:41 AM #913
      Thanks!! Looking forward to see this car back together


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      09-10-2020 06:27 PM #914
      After talking with my buddy T. He got me worrying that I didnít measure the ring gaps. Even after a bunch of people said Iíll probably be fine. Me and my ever growing anxiety about this car would have me thinking what if. So I pulled it all apart and yep they were fine and within spec.
      I did however manage to get the rear main seal housing bolted on while the motor was light enough to lift off the stand and onto the bench.
      Also got the oil pump installed as well as a new windage tray and baffle.

      Now I just need to wait for the new head gasket to show up and I can bolt it back together.



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      Last edited by vwjunkie42; 09-10-2020 at 07:31 PM.

    16. Member
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      09-12-2020 09:22 AM #915
      That peace of mind will be worth it. Looking good


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      09-16-2020 05:34 PM #916
      Got the new gasket in today. As well as the last few bits.
      So I bolted down the head.

      And got everything all timed up again.

      Now that itís an aba block I can use all four studs for the serp setup. So I managed to find a nos spacer stud.

      Also with the aba comes crank trigger wheel. So I got a sensor to put in the hole for now. Itíll allow me to go distributor less in the future. Iím not going to do it now but like that I will have a clean way of doing it if and when I decide to.

      The lower timing cover is with my buddy joe being fixed up. Once heís done it can go back in the car.



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    18. Member
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      09-16-2020 10:06 PM #917
      Wow looking great! Canít wait to see it come back together


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    19. Member
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      09-17-2020 11:50 PM #918
      Iíve been toying with the idea of a smoothed valve cover so I found another one and set out to smoothing.
      First cut off the weird tabs and smoothed out the casting flash along the edge.
      Then milled down the fins and sanded it all smooth.



      Than sand blasted it to give it an even texture

      Finally hit it with a good thick coat of the epoxy paint



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    20. Member
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      09-19-2020 11:08 AM #919
      Finally finished up the valve cover experiment and I like it.

      Gave the paint a couple of days to cure then scraped off the paint on the tops of the plug holes. I wanted to retain the raised rings as the plug wires donít sit quite right with out them and it looks odd. Long ago I had completely smoothed one and polished it. If you look way way back itís in the orange motor that the 9a replaced.
      Anyway...... I then blocked them with my tiny stone and an array of different grit sand paper from 220-2500.

      Then hit it with just a tad of polish.

      I really like how it came out. It looks exactly how I pictured it in my head. Lol


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    21. Member
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      09-19-2020 09:42 PM #920
      Loving it


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    22. Member
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      09-20-2020 12:35 AM #921
      My man joe killed it with the plastic repair. Completely replaced the missing tab and Bushing.

      Now that I have the timing covers back on, technically the motor can go back in. I may do that tomorrow morning.




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    23. Member
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      Today 01:02 AM #922
      Spent a little time on Sunday and Monday morning. Getting the motor in.



      And one of the things I was worried about seems to not be a problem.


      The header still seems to fit with some room to spare. I was worried that with the taller block I would run into clearance issues.


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