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Post by gitrdun on Jul 11, 2012 19:45:15 GMT -5
My stock 1600 motor siezed up solid on me after a 4 mile stretch at highway speeds, 70mph. Aparently it ran out of oil as it was dry when i checked it after the fact. I had checked it about 5 times previously and it hadnt used a drop but the one time i went for a spin and didnt check wouldnt you know it.
Anyways, i had a big bore motor (1835) sitting in the garage needing new cylinders and pistons so i thought this was a good time to upgrade the power dept. I installed a new set of pistons and cylinders and installed the motor in the car. On initial fire up the motor has a hard knock. I disconnected the plug wires one at a time and nothing changed, checked the valve lash and watched the valves as the engine ran. Im thinking it must be a crank problem or cam shaft. I also switched distributors and checked timing. The noise seems to be eminating from the drivers side of the engine but its hard to tell.
Is there anything else i can check to diagnose the problem before removing the engine and going through an entire tear down?
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Post by Tony O. on Jul 11, 2012 19:57:03 GMT -5
Based on my own prior experience, if it is a continuous knock while idling, IMHO it is probably a connecting rod bearing gone bad.
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Post by jspbtown on Jul 11, 2012 20:27:35 GMT -5
Could be a loose flywheel.
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Post by gitrdun on Jul 12, 2012 21:21:44 GMT -5
It does sound like a rod knock, but ive never had a rod that knocked continuously. They usually would stop knocking when you throttle up fast and then hammer like heck on deceleration. I put it in gear and ran it back and forth a bit and the knock stayed constant so i dont think its a flywheel problem.
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Post by Gary Hammond on Jul 12, 2012 21:40:37 GMT -5
Hi,  Did you check the deck clearance when you installed the new cylinders and pistons? Should be a minimum of .040" clearance between the piston and head. Gary Hammond,   |
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Post by Dan MacMillan on Jul 13, 2012 8:44:43 GMT -5
Can you post a video so we can hear it. Startup, idle, slow accel to 2000, quick accel to 2000, all in neutral. Then a light brake torque.
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Post by gitrdun on Jul 14, 2012 11:41:52 GMT -5
No, i did not check the deck clearance. In my haste i must have completely over looked it, i hadnt even thought of that. That and it was 1AM and 3 beers when i assembled the motor. I will pull the heads and take a look.
I will see if i can shoot a quick vid before taking the heads off. The knock is constant at idle, high idle, accel, and decel. Even in gear letting out on the clutch and moving forward or reverse. It has to be something with the crank, a rod, or piston.
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Post by Dan MacMillan on Jul 14, 2012 14:45:17 GMT -5
Did you try running it briefly without the fan belt?
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Post by gitrdun on Jul 14, 2012 16:22:43 GMT -5
I did try running it with the belt off.
I removed the heads and one cylinder has less than .010" deck clearance. The rest look pretty even around .03 maybe. No signs of any contact with anything and the low clearance piston hast been chipped away or over heated on the edge. I downloaded a compression calculator and at .03 clearance i should be around 9.9:1. I will need .125" clearance to get to 7.7:1. Wow. Is that normal?
Now i hope i can find shims for a 92.5mm piston cylinder.
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Post by skip20 on Jul 14, 2012 16:35:42 GMT -5
My very 1st job when I went though Mech. school was a VW bus which had a bad piston.
The teacher agreed & we order a new one.
Got it installed & started right up.
BANG BANG BANG.
Out came the engine & heads.
Guess what? Somebody had decked the heads .10, Did the repairs & back in & ran great.
This is why "I HATE VW"
They make 10,000 after market parts for it & you never know what someone has done.
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Post by gitrdun on Jul 15, 2012 10:43:33 GMT -5
Well the short story, it runs great. The long story, in a quick net search i wasnt able to find the shims i needed for my over sized cylinders. local auto parts stores dont carry the brass shim paper like you used to get for making gaskets. So i bought a sheet of .025" thick galvanized steel. I cut a ring out of it just the right size and it fit perfect. Put everything back together with the spacer on the low cylinder and it runs great with no hint of pinging or knocking. And boy does she have some power at 1840cc and around 10:1 compression. Sounds awesome to.
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Post by skip20 on Jul 15, 2012 12:46:23 GMT -5
That sound GREAT! Now get out on the road & have fun. |
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