GarytheGolf
Posted
Settled In
![andywolves in the usergroup ‘Local’ andywolves in the usergroup ‘Local’](https://vwgolfmk1.org.uk/themes/default/images_custom/ylV8bhM.png)
GarytheGolf
Wow!! incredible work there malc, wish i had your expertise.
I really need to do what your doing as my engine has done 171k miles but i havn't got the confidence to strip the engine down to its bare bones.
Great work almost new engine when youve finished.
Is that a matt black engine enamel that you have used?, it looks so clean.
Keep up the good work
regards andy
![:)](https://vwgolfmk1.org.uk/themes/default/images/ocf_emoticons/smile.png)
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
Put piston Nos 1 and 4 first.
Lubricated the conrod journal and placed a piece of Plastigauge across the journal.
![gary524.jpg gary524.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516735429/uploads/attachments/5a678bc3b9da0.jpg)
New shell in place for the conrod cap.
![gary526.jpg gary526.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516735431/uploads/attachments/5a678bc769165.jpg)
Torqued down the conrod cap and then removed it.
You can see how the plastiguage has spread out. This width was measured using the supplied gauge and it equaled 2 thou. Well in tolerance, as new.
![gary531.jpg gary531.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516735434/uploads/attachments/5a678bc9e4533.jpg)
Refitted the cap and torque loaded. All four pistons in place. All mid stroke.
![gary532.jpg gary532.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516735437/uploads/attachments/5a678bcd0f5ca.jpg)
For the moment, I have stored the engine upside down and filled the pistons with some clean engine oil.
![gary534.jpg gary534.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516735440/uploads/attachments/5a678bcfa6264.jpg)
Weekend fix over. That's it for about a fortnight. Xmas shopping next weekend. Hope to get the sump, cylinder head and timing gear back on next.
Last edit: by Malcolm
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
Only managed to paint the sump with POR 15. Hope to do better next weekend.
![gary535.jpg gary535.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516713733/uploads/attachments/5a673702360fc.jpg)
Last edit: by Malcolm
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
I replaced the front and rear crankshaft seals with new. Both new seals were VW.
Out with the old (right) and in with the new (left) front.
![gary541.jpg gary541.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734882/uploads/attachments/5a6789a1006b1.jpg)
Out with the old (brown) and in with the new (black) rear.
![gary536.jpg gary536.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734884/uploads/attachments/5a6789a43bbf5.jpg)
To fit the rear seal housing, I had to take the engine block of the stand.
![gary537.jpg gary537.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734887/uploads/attachments/5a6789a6b5072.jpg)
![gary538.jpg gary538.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734889/uploads/attachments/5a6789a93385e.jpg)
Refitted the block onto the stand and the front seal housing onto the engine block.
Flushed out the oil pump and filter and installed the pump, surprisingly no gasket. Primed the pump.
![gary540.jpg gary540.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734892/uploads/attachments/5a6789abc2ab6.jpg)
Fitted the sump pan with new gasket. Sump is POR 15'd.
![gary542.jpg gary542.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734894/uploads/attachments/5a6789ae50c93.jpg)
Turned the engine over and installed the cylinder head with new gasket and bolts. Front crankshaft seal housing installed.
![gary543.jpg gary543.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734897/uploads/attachments/5a6789b11ce82.jpg)
![gary546.jpg gary546.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734900/uploads/attachments/5a6789b40200a.jpg)
Proper tool for the head bolts, 12 spline not 6.
![gary549.jpg gary549.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734903/uploads/attachments/5a6789b6e50f6.jpg)
The cylinder head tightening down procedure is quite complicated. Starting from the middle bolts outwards, 40 Nm torque, 60 Nm then 75 Nm, then add a further 1/4 turn. It gets really tight towards the end.
![gary544.jpg gary544.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734907/uploads/attachments/5a6789baba14c.jpg)
![gary548.jpg gary548.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516734910/uploads/attachments/5a6789bd8386d.jpg)
Light getting low, time to pack up. Pretty happy
Last edit: by Malcolm
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
Distributor and fuel pump added.
![gary550.jpg gary550.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714608/uploads/attachments/5a673a6f7909d.jpg)
![gary558.jpg gary558.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714610/uploads/attachments/5a673a722ff8c.jpg)
Parts cleaned and sprayed with engine enamel.
![gary561.jpg gary561.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714613/uploads/attachments/5a673a74db16d.jpg)
![gary563.jpg gary563.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714616/uploads/attachments/5a673a77b7b09.jpg)
Note the new water pump half. I originally purchased this years ago for my Mk2.
![gary560.jpg gary560.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714618/uploads/attachments/5a673a7a2b0fb.jpg)
Two halves of the water pump assembled, unfortunately with original gasket sealed with Hylomar sealant.
![gary564.jpg gary564.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714621/uploads/attachments/5a673a7ce44ec.jpg)
The black bolt is a replacement, the original had sheared, I had to drill the broken bolt out and retap a new thread.
![gary565.jpg gary565.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714624/uploads/attachments/5a673a7f6cb68.jpg)
I hope to get some of these parts back on the engine, time and fit the cambelt tomorrow.
Last edit: by Malcolm
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
Whilst fitting a new cambelt and tensioner, I decided to use a small paint brush in the No.1 cylinder so I could see it rise to TDC.
Imagine my horror when a piece of the paintbrush handle broke inside the cylinder !!. I tried all sorts of things to get it out, including a blob of grease on a metal rod.
I eventually managed to find my extending grabber. I could pick the paint bush hanldle up, but could not get it out through the spark plug hole. It was like a dog trying to get a branch through the gate.
I had just decided to take the head off again, when I thought I would give it another go. The pictures say it all !!
![gary566.jpg gary566.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714331/uploads/attachments/5a67395a8bf31.jpg)
![gary574.jpg gary574.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714333/uploads/attachments/5a67395d30292.jpg)
In addition today, I did manage to fit the cambelt and tensioner.
![gary572.jpg gary572.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714336/uploads/attachments/5a67395fc66aa.jpg)
![gary573.jpg gary573.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714339/uploads/attachments/5a6739629168a.jpg)
The inlet manifold, water pump, oil filter mounting and water tapping with some stainless steel bolts.
![gary569.jpg gary569.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714341/uploads/attachments/5a673964eca8f.jpg)
Last edit: by Malcolm
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
Posted
![Avatar](https://i259.photobucket.com/albums/hh319/brucie_boy/Photo157-1.jpg)
Local Hero
![brucieboy in the usergroup ‘Local hero’ brucieboy in the usergroup ‘Local hero’](https://vwgolfmk1.org.uk/themes/default/images_custom/2T6Iw1M8.png)
![](https://i259.photobucket.com/albums/hh319/brucie_boy/sig-2-1.jpg)
Weber,ATS,Apex,Ripspeed,Supersprint,K&N MOMO..tbc
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
As I do most of my work outside, I feel that the weather will limit the progress over the winter period.
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
I have come to the point where I am fitting things onto the engine and find that they need derusting, pickling and painting.
A little logistics of keeping the items and the paint warm before spraying outside seemed to be the best approach.
Though the wife is complaining about the smell of paint whilst they dry in the house with being too cold outside.
![gary575.jpg gary575.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516713918/uploads/attachments/5a6737bd784cf.jpg)
![gary578.jpg gary578.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516713920/uploads/attachments/5a6737c00a588.jpg)
![gary579.jpg gary579.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516713923/uploads/attachments/5a6737c26fc4d.jpg)
![gary583.jpg gary583.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516713926/uploads/attachments/5a6737c58fb5e.jpg)
Last edit: by Malcolm
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
With Xmas and family commitments out of the way, I managed to have a normal weekend and did a few hours on the car today.
A bit of personal admin, finding parts, I managed to fit some of them.
Trying to put everything back together seems a bit of a jigsaw despite having all the manuals, Etka and Elsawin, particulary around the cambelt area.
A couple of photos representing todays work.
![gary589.jpg gary589.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516713981/uploads/attachments/5a6737fd58675.jpg)
![gary590.jpg gary590.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516713984/uploads/attachments/5a67380013983.jpg)
Last edit: by Malcolm
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/20160605_084816191_iOS.jpg)
Local Hero
![Hairyarse in the usergroup ‘Moderators’ Hairyarse in the usergroup ‘Moderators’](https://vwgolfmk1.org.uk/themes/default/images_custom/OeIGBY0.png)
![Hairyarse in the usergroup ‘Paid Member’ Hairyarse in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Hairyarse in the usergroup ‘Regional Hosts’ Hairyarse in the usergroup ‘Regional Hosts’](https://vwgolfmk1.org.uk/themes/default/images_custom/MkOEmwK.png)
![Hairyarse in the usergroup ‘Local hero’ Hairyarse in the usergroup ‘Local hero’](https://vwgolfmk1.org.uk/themes/default/images_custom/2T6Iw1M8.png)
![;)](https://vwgolfmk1.org.uk/themes/default/images/ocf_emoticons/wink.png)
Andy
LINCOLNSHIRE REGION - https://www.facebook.com/groups/467122313360002/
1983 MK1 Golf GTI Campaign Model - Under (looooong) resto!
1962 Rover P4 80
2002 BMW 745i
2008 BMW Z4 2.5Si
LINCOLNSHIRE REGION - https://www.facebook.com/groups/467122313360002/
1983 MK1 Golf GTI Campaign Model - Under (looooong) resto!
1962 Rover P4 80
2002 BMW 745i
2008 BMW Z4 2.5Si
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
Posted
![Avatar](https://vwgolfmk1.org.uk/themes/default/images/ocf_default_avatars/default_set/forks.png)
Old Timer
![djheap22 in the usergroup ‘Old timer’ djheap22 in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
![:D](https://vwgolfmk1.org.uk/themes/default/images/ocf_emoticons/grin.png)
1988 1.8 carb Golf Clipper
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
Posted
![Avatar](https://i572.photobucket.com/albums/ss163/79-85/players-2010-063.jpg)
Settled In
![79-85 in the usergroup ‘Local’ 79-85 in the usergroup ‘Local’](https://vwgolfmk1.org.uk/themes/default/images_custom/ylV8bhM.png)
thanks for the help with the gravity valve bracket. 8)
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/NK785B-1-1.jpg)
Old Timer
![Malcolm in the usergroup ‘Paid Member’ Malcolm in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Malcolm in the usergroup ‘Old timer’ Malcolm in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
A little bit done today, still on the engine. Trouble is finding the items to fit. They are in the garage somewhere.
Torque loaded all the manifolds, oil filter housing, water and fuel pumps. Connected some water and fuel hoses, replaced some bolts with stainless steel.
![gary602.jpg gary602.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714106/uploads/attachments/5a67387a6106c.jpg)
![gary604.jpg gary604.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714109/uploads/attachments/5a67387cdfb09.jpg)
The strap between the inlet and exhaust manifold has corroded quite badly. A work colleague made me a new one out of stainless steel.
![gary599.jpg gary599.jpg](https://res.cloudinary.com/mk1-golf-owners-club/image/upload/c_limit,w_768,f_auto,q_auto/v1516714111/uploads/attachments/5a67387f3b10c.jpg)
Enough for today, still quite cold despite 4 layers on.
Last edit: by Malcolm
Posted
![Avatar](https://vwgolfmk1.org.uk/uploads/ocf_avatars/20160605_084816191_iOS.jpg)
Local Hero
![Hairyarse in the usergroup ‘Moderators’ Hairyarse in the usergroup ‘Moderators’](https://vwgolfmk1.org.uk/themes/default/images_custom/OeIGBY0.png)
![Hairyarse in the usergroup ‘Paid Member’ Hairyarse in the usergroup ‘Paid Member’](https://vwgolfmk1.org.uk/themes/default/images_custom/7vW13sh.png)
![Hairyarse in the usergroup ‘Regional Hosts’ Hairyarse in the usergroup ‘Regional Hosts’](https://vwgolfmk1.org.uk/themes/default/images_custom/MkOEmwK.png)
![Hairyarse in the usergroup ‘Local hero’ Hairyarse in the usergroup ‘Local hero’](https://vwgolfmk1.org.uk/themes/default/images_custom/2T6Iw1M8.png)
![;)](https://vwgolfmk1.org.uk/themes/default/images/ocf_emoticons/wink.png)
Andy
LINCOLNSHIRE REGION - https://www.facebook.com/groups/467122313360002/
1983 MK1 Golf GTI Campaign Model - Under (looooong) resto!
1962 Rover P4 80
2002 BMW 745i
2008 BMW Z4 2.5Si
LINCOLNSHIRE REGION - https://www.facebook.com/groups/467122313360002/
1983 MK1 Golf GTI Campaign Model - Under (looooong) resto!
1962 Rover P4 80
2002 BMW 745i
2008 BMW Z4 2.5Si
Posted
Old Timer
![watson in the usergroup ‘Old timer’ watson in the usergroup ‘Old timer’](https://vwgolfmk1.org.uk/themes/default/images_custom/XW2jYK6.png)
0 guests and 0 members have just viewed this: None.