Club 80-90 Forums

Thanks I use this which is far easier because it's illustrated and more trustworthy because it's a VW publication.

I haven't checked valve diameters, just the play page 15.18

http://syncrosport.com/info/manual/VW_T ... hanics.pdf" onclick="window.open(this.href);return false;

That's a seriously useful link. Downloaded & saved

Thank you

937carrera wrote:That's a seriously useful link. Downloaded & saved

Thank you

To be fair most of it is in Bentley too, but thats free.

Has anybody got and tried and trusted way of removing compression seals / fire rings without resorting to a screwdriver, I have scratched too many heads before?

P1080844 by Paul_Barr, on Flickr

Yep just tried this on an old head, gently heat combustion chamber with blow lamp to expand the bore squirt wd 40 through the tube onto the fire ring to shrink and out it will pop, well mine did and it was stuck before, good luck.

That should work - you can also try a feeler gauge instead of a screwdriver.

weimarbus wrote:Yep just tried this on an old head, gently heat combustion chamber with blow lamp to expand the bore squirt wd 40 through the tube onto the fire ring to shrink and out it will pop, well mine did and it was stuck before, good luck.

Thanks weimarbus heat worked but I didn't need to spray it.

I heated the ring by going round in circles with the torch, the ring expanded and buckled lifting in one place than easy to lift out

Not a scratch in sight.

P1080852 by Paul_Barr, on Flickr

P1080851 by Paul_Barr, on Flickr

P1080853 by Paul_Barr, on Flickr

Watching with interest Paul, looks like a nice easy job getting those out

300CE wrote:Watching with interest Paul, looks like a nice easy job getting those out

Everything is easy when you know how, it wasn't immediately obvious to me and I have done quite a few head seals in the past.

Its why I try to share what I have learned, I bet others have strugged with this too.

There's not much point in getting older if you don't hopefully get a little wiser. The last time I thought 'it's only a little scratch' it led to pressurising the coolant around 10,000 miles later and scrapped heads.

Cleaned up head 1&2 today and ground valves, inlet for No2 would not grind it's had it, burnt by the looks, maybe lean the deposits were rock hard, found a good valve from a scrap head and swapped it over.

so that explains low compression on No2


No1 10 bar ( leaking oil out of plug hole)
No2 8,75 bar ( worn inlet valve)
No3 9 bar ( broken rings)
No4 11 bar

P1090029 by Paul_Barr, on Flickr

Have you any pics of the worn valve and seat?

what2do wrote:Have you any pics of the worn valve and seat?

hard to photograph, seat is fine the valve is degraded so a 10-15mm section is not ground.

P1090032 by Paul_Barr, on Flickr

I decided to swap both inlet valves as I wasn't happy with the other either.

Valves refitted.

P1090033 by Paul_Barr, on Flickr

The inlet valves on the other are just as bad so I didin't even bother trying to grind them, I just swapped them with some from another head.

P1090034 by Paul_Barr, on Flickr

P1090040 by Paul_Barr, on Flickr

I really want this out of the shed before the camping season starts so need to crack on.

I need a parts list as it's not my engine so I want all the bits ordered

End float is way too much so removed the flywheel to see whats happening

P1090517 by Paul_Barr, on Flickr

quite oily not helped by the usual groove in the flywheel

P1090518 by Paul_Barr, on Flickr

I like to cut the lip off the seal so I can see what I'm doing

P1090519 by Paul_Barr, on Flickr

punch the seal in a few places taking care not to slip off, it releases it

P1090521 by Paul_Barr, on Flickr

lever it out

P1090523 by Paul_Barr, on Flickr

looks reasonable, no disasters

P1090524 by Paul_Barr, on Flickr



large shim should be 0.4mm this is where most of the wear is

P1090526 by Paul_Barr, on Flickr

other two are both 0.37mm

I had a new 0.4 'in stock' so tried it

o ring out first

P1090525 by Paul_Barr, on Flickr

gone too far 0.02mm ( want 0.07 to 0.1mm ideally, lower end of the range)

P1090529 by Paul_Barr, on Flickr

swapped a 0.37 with a 0.32 I had 'in stock'

thats good

P1090530 by Paul_Barr, on Flickr