Budget CU rebuild

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Budget CU rebuild

Postby sarran1955 » 06 Sep 2019, 19:38

Hello Boys and Girls,


A little bit of air-cooled fun.. :)

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Well here we are last week end in the dying moments of the French school Summer holidays..

My new school bus, the latest Renault, with ecodrive,Adblue, .....and air conditioning.. 8) is in place..

My red 1700 T3 is going very well, better performance, 26mpg perhaps 65 bhp, and not a drop of oil..

and peeping out shyly from behind is 'Pop Eau' with a 70's Cu motor in a CT chassis, owned by Maxime, a local club member..

]Image

The motor displays all the classic symptoms, oil leaks every where, smoke from the crankcase breather, down to 85 psi on 3 and 4... :(

but plenty of oil pressure and a reasonable budget.. :)

So the deal is : he does the donkey work and pays for parts, I do the twiddly bits, and then we do the same thing on the next CT that I have in line.. :wink:

Here we are in the shop with most of the preparation done..

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So essentially the job consists of:

crankcase front oil seal

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crankcase rear oil seal

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Cylinder head

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with new valve guides:

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and stainless exhaust valves:

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So far, so good....

Air-Cooled Bliss.. 8)

Cordialement,

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby King Kenny » 07 Sep 2019, 16:44

Nice project. I am sure you will do a good job. Wish I could watch you both working, but I will have to make do with following your posts.
I don't know where I am, but I'm having a lovely time!

1990 CARAVELLE 1.9cc petrol : watercooled
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Re: Budget CU rebuild

Postby sarran1955 » 07 Sep 2019, 18:09

Hello,

A gentle Saturday, where the temperature has dropped from T shirt and shorts to shirt and jeans..

so the pistons for the above head..

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Alles in Ordnung.. :)

But on the other side.. :shock: :shock:

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Both pistons are damaged, with metal debris swept in through the inlet ports....

a great hammering in the combustion chambers...

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I am pointing to a piece of embedded steel.. :shock:

So, a big dent in the budget of 295€ for new pistons and barrels...

but the good news is we can go from dished to flat pistons..better CR..justifying 98 RON petrol..

The damage is smoothed out with a die grinder and WD 40..

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This head will be lapped with an old barrel before fitting the new decompression ring.. :wink:

So the next step is to renew the valve guides..

The essential tools...

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This is a 2 step process, using an adjustable hand reamer, where 1st the head has to take the new valve guide, was 12.02 is now 12.08 mm


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The reamer is wound out cutting just large enough to give a tight fit..

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So that the valve guide can be gently drifted into place..


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Next the guide has to be reamed internally so that the new valve will run smoothly,

But that is all for today... :roll:

Air-Cooled Bliss... 8)

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby asterix_the_gaul » 12 Sep 2019, 19:00

Thanks, reading with interest.. How long did it take you to get the engine out and ancillary stripped for the rebuild?
Autohomes CI Kamper 2.0 CU air-cooled
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Re: Budget CU rebuild

Postby sarran1955 » 17 Sep 2019, 10:15

Hello,

asterix_the_gaul wrote:Thanks, reading with interest.. How long did it take you to get the engine out and ancillary stripped for the rebuild?



Here is a video for you, CT or CU it is all the same, but remove the throttle return spring bracket before dropping the motor.

https://www.youtube.com/watch?v=JGC3EZXa644

On my own, I can have the engine out and in the trailer in about 1 hour.

Stripping the engine, cleaning painting and refettling has taken Maxime, a VW debutante, 2 Saturday mornings.

Now that the pistons have arrived, I can start the build up, I've spent 2 Sat mornings overhauling the cylinder heads so far,
and hope to progress this week end, the unknown factor being the tinware, as most of it was missing, and is being sourced 2nd hand

I may well have to fabricate some plates.. :roll:

T shirt and shorts weather again.. :)

Air-Cooled Bliss.. 8)

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby sarran1955 » 17 Sep 2019, 10:23

Hello KK,

King Kenny wrote:Nice project. I am sure you will do a good job. Wish I could watch you both working, but I will have to make do with following your posts.


Nice to hear from you, I was too busy to come to Normandy this Summer, due to another serious attempt at the 24hrs trophy..

]Image

But if you want to come and play VW's you're most welcome....

Plenty of room.. :)

Autumn colours, mushrooms and chestnuts... 8)

Cordialement,

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby sarran1955 » 23 Sep 2019, 12:55

Hello,

Well here we are on the first day of Autumn...

and we had a timid rain fall yesterday, breaking a 3 month drought... :)

So.. back to the CU motor,

Firstly, can any one tell me the year..nr CU 058886.. :?:

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Lapping in the new stainless steel exhaust valves is made much easier and quicker by using a cordless screwdriver and a flexy pipe

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Here is the result..

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The rocker bar studs were replaced, real one on the left, PO bodges on the right..

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Meanwhile in the paint department, the finishing touches are applied to that well known german exhaust... :?

the IdW3..

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Just my little German Joke... :)

The motor goes on the build up stand..

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The engine was leaking too badly to diagnose when in the vehicle..

This may be part of the problem...

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I think we will consider that sealant to be a bit enthusiastic.. :roll:

Note also the wrong oil seal and the crushed strainer..

As the CU drain plug was rounded off..
I fit the new standard VW oil drain plug..

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However,

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the underside of the motor is not too bad, with no scrape marks on the outer 'horns' , but the relief spring cap washer is badly fitted. The sump plug thread has been
Heli-coiled and the hanging bolt for the strainer is straight..

Handy tip, use a big washer and lever to undo the plug.. :wink:

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This one already has 2 'love bites'... :oops:

I am not removing the other plate, as there is damage to the case, which makes the plate a horror to replace oil tight...believe me..

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The clutch and fly wheel are de-glazed with a 50 mm air sander...

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The oil cooler is fettled..

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then filled with thinners and left overnight..

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Finally sort another broken stud..

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I think we are ready to start the build..

Air-Cooled Bliss.. 8)

Cordialement,

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby Asw » 23 Sep 2019, 19:59

Can I just say . I want your workshop and toolkit!!! I know I can’t weld or paint but know I could do so much more.
I have asked the garage who did my body work and mots to do work because it was cheaper to pay him than rent a garage and the specialist tools.
Ultimately, are we not all air cooled?
1981 Devon Moonraker, CU engine
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Re: Budget CU rebuild

Postby sarran1955 » 24 Sep 2019, 17:59

Hello,

Just to start the rebuild,

the oil strainer, plate and nuts are all cleaned.

I think the crush washer has seen enough service.. :roll:

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The components are assembled DRY..no goop.. :wink:

Then the crankcase has 1 pint of oil put in through the oil filler, you can see the level..

Image

This is now left over night..

]Image

If the crankcase is oil tight, then we can continue..


Cordialement,

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby sarran1955 » 26 Sep 2019, 17:36

Hello,

Well the crankcase remains oil tight.... :)

Here are the videos of how to do the head rebuild:

Part 1: https://www.youtube.com/watch?v=iGolJzpQVr4

Part 2: https://www.youtube.com/watch?v=GNVsVk4QI3o

Enjoy....

Air-Cooled Bliss... 8)
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby sarran1955 » 27 Sep 2019, 13:39

Hello,

Well the good news is that the crankcase seems oil tight... :)

]Image

So now the AA pistons and barrels come out of their boxes..

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They are faithful copies of the Mahle , and I check that the piston rings are correctly staggered..

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Prepare the piston and circlips..Buy yourself a decent pair of pliers.... :wink:

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Here is a piston and cylinder all aligned for easy fitting. The shim is in place..

]Image

There will be a video of all this... :roll:

Air-Cooled Bliss.. 8)

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby sarran1955 » 29 Sep 2019, 19:06

Hello,

Well, the sunshine is back and Autumn is here with golden leaves and crystal clear views.. :)

So on the motor we fit the oil cooler, filter and filler pipe..

Image

Then the tin behind the oil cooler..

Image

Then the pushrods,tubes and rocker assembly..

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Now is a good time to test fit the heat exchanger, the studs had to be re-aligned to avoid future struggling ..

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Then test fit the under plate..

]Image

I think this is the panel in Unobtanium alloy.. :roll:

Air-Cooled Bliss.. 8)

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby sarran1955 » 06 Oct 2019, 20:37

Hello,

Well another week end of air-cooled fun..

So with the static valve timing set, the rocker boxes go on..

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Then the rear oil seal..

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and the spacer..


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then the new front crankcase seal..

]Image

New crankcase to bell-housing studs are made and fitted..

]Image

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The flywheel oil seal..

]Image

The flywheel can then be torqued..

So onto the heat exchangers and under tins..

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then fit the 'Jules Fandango' exhaust..


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I remade strengthening brackets for both sides..

Image


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and had to substitute Eberspacher hose for the missing tinware....yes it clears the zorst.

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All 'tinned up' and ready for carbs and ignition..

Image

]Image

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So that is it for this evening...

Air-Cooled Bliss... 8)

Cordialement,

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby sarran1955 » 21 Oct 2019, 10:25

Hello,

Well this week end it is start and run time..

The engine has been built up ready for first start.

To help prime the motor, the sump is filled to the bottom of the dipstick, the oil filter is filled, and the oil cooler filled:

]Image

The oil pressure gauge is screwed in..

and note the SVDA Powerspark dizzy, with 'D' washer..

The motor started with no fuss, but I only ran it for 2 mins before re-adjusting the tappets..

Handy tip..if you only fill the sump to the bottom of the dipstick, the oil will not pour out of the rocker boxes when you are adjusting the valve clearances .. :wink:

Tappets at contact plus 1 turn.
Engine oil for initial start up 10w40 HD diesel engine oil, to flush out the engine and smells..

Rear view:

]Image

Servo side view:

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Alternator side view:

]Image

So the engine has now run for about 40 mins, using a good 3 litres of 95 RON...

and the good news is....NO oil leaks

there is a little bit of crankcase pressure, but I will wait for the pistons and cylinders to bed in.

Oil pressure 1.2 bar at tickover, 3 bar at 2000 rpm... :ok

The slow part of the project was finding the missing tin ware, and building one decent pair of carburettors from 5 donors... :roll:

Oh..and yes the EMPI exhaust is QUITE LOUD... :rofl :rofl

I have all the videos 'in the can', and will E D I T them soon.

We will install the motor in the school hols starting this week.. :)

Air- Cooled Bliss.. 8)

Cordialement,

:ok
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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Re: Budget CU rebuild

Postby sarran1955 » 06 Nov 2019, 16:50

Hello,

After editing and up loading a Ferodo Transient :roll: worth of video,

Here is the link to part 1 of this Summer's CU rebuild

https://www.youtube.com/watch?v=uRXNqBHH-LE

Enjoy....

Air- Cooled Bliss.. 8)
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0
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