Richard & Mustards Engine Build

Mustard Man · Richard & Mustards Engine Build

Hi all,

I’ve decided to try and build myself an engine from new and used parts to replace the one I have currently and thought it would make a good progressive blog as the build happens, so here we go.

I’ve got a 1600 in Mustard at the mo, but I’ve oil leaks here and there, and odd knocking noises that I won’t be able to sort until it comes out, so I recklessly decided that I’d just start again from new, and build a new one… Very Happy

..the idea being it would give me the knowledge to rebuild my old, and also minimise time off the road, as its also my daily driver.
An ambitious project for someone that’s never really done anything like this before. But I was always good with lego as a kid so it can’t be that different??!!?? Can it…… Confused

Anyway, I’m trying to keep things similar to minimise change, so have bought a new 1600 block that’s been machined out to 1835cc with new heads etc and a new mild cam to fit. Everything else is fairly standard really, but I’ve added things like a heavy duty fuel pump, external oil cooler and I’ve bought the new Petronics Dizi, Coil and leads that have been getting great reviews. And yes the banks are getting worried for me already…… Rolling Eyes

Below are pics of most the bits after I’d picked them up, and couldn’t resist getting them all out and looking at it all.

To aid me in this slightly crazy project of mine, I’ve got hold of the ‘Bug Me’ Videos (on DVD thankfully) where they have recorded and described a full break down and rebuild on a 1600 engine….it’s really good to be able to see what they do and its full of tips and hints etc.

So, I’ll update with progress reports and photos as I go, and probably questions and pleas for help and ‘what was I thinking’ moments. Hoping to get started this weekend……fingers crossed

Scotia

shiney bits - I like it already Razz

good luck with the build, you've got lots of guys here to advise you when ..oops sorry I mean
if you get stuck.
Hope you had a good holiday look forward to hearing about it next Alfreds.

VLKSWGN

Nice one Colmans, Im well jealous Embarassed

All the best with your rebuild,
I may even get of my arse n try n ave ago myself with the green machine!

Im gonna watch this blog!

Steve

BJ

Like Lego? Laughing

Good luck Rich, I am gonna watch this too....break it down like James Brown for us. I guess we could borrow the DVD afterwards.

All the best.....

Archeress

Good luck...this is going to be one to watch... Very Happy

samblers

wow - looks like you got new everything!

good luck with the rebuild Very Happy

Diddlie

I didn't know Ikea did kombi engines. You know there will be a bit left over don't you!!

Keith D

Good on you Rich!

Putting your new parts on a sheet and photographig them is a brilliant idea. I've done this myself very often during restorations. There is something about newly machined parts that just gets to me!

Remember that the money you spend now is a once off thing. The pleasure you get from the restored motor will last for years - long after the cost is forgotten. Watching Kombi folk at Muresk last weekend is proof of this!

Keep the enthusiasm and photos flowing! - Keith D

Mustard Man · Engine Build Update

So,

At last i've managed to block a day off to start the engine build.

Started off with the crank shaft, and getting all the gears and berrings on, had some funny looks of my house mate while heating the gears up over the kitchen hob, (need to heat them up to expand them so they fit on and then lock tight.

Then i got the rods on and touqued everything up, and had my self a finished crank. All fairly easy, apart from a few probs with only two hands and a few trial and error bits. Biggest prob was getting the top securing washer on, thought i was gonna loose a finget doing that.

See Pics below of the finished crank!!

Mustard Man

Next, i set the case up, with the dowel pins, and the split berring, and dropped the crank into place,

piece of advice here, put all your berring in the case at the start and mark up where they fit into the pins, (each berring has a little hole, and this fits into a pin in the case so they can't spin, you can see on the pics before.) then once they are in, mark them with a permant marker so later when they're on the crank and your lowering it into the case it easier to fit the holes you now can't see into the pins...)

Naturally i didn't do that, and spent about 15 mins, lifting and realigning etc......

Once this is in, you can spin it around and everything.....very exciting.

Oil everything lots, and double check everything.....otherwise this was also easy really, i imagine next time i could do all this in about an hour!

See pics below of crank sat in the case.

Mustard Man · Cam shaft in

Right, next was the cam shaft.....I'd got myself a mild cam to put in, so after cleaning all the new cam berrings and cam itself,

(anything thats new seems to have a coat of something on it, i guess to protect it, so using Mineral spirts and then warm soapy water i cleaned anything that was new, or just dirty before)

Then i got these into the case, oiled it all up and sat the cam in. There are two dots on the main gear on the crank, that you line up with the dot on the cam shaft gear. Once lined up you can roll it down and into place.

Now you can rotate the crank, and besure it all sits right, and freely goes round. It did!! Woo Hoo.

See Pics below!!!

Mustard Man · I missed something

So,

Once this was all in and i was happy, it was time to put the other half of the case on and lock it all up.

So, i'd got the O rings for the 6 main rods out, but there were only 4?? Whats that about, brand new gasket kit, and im missing 2 O rings?

After a trip to bunnings and the plumbing section i got the O rings on, permatexed the case seal, dropped in the tappets and put the case on.

Now, this is tricky as you need to find a way to keep the top tappets in place as you lower the top into place.....tried numeros ways, like bent coat hangers and clothes pegs but ended up with a piece of paper and sticky tape?

Then, just as i'd lowered the top on, i suddenly realised i'd forgetten to check the gap between the main berring and the case.....Here i was meant to put in some shims (big washers) leaving a gap of .004 of an inch. So you have to measure the overall gap, minus the .004 and fit shims in to cover the rest......

Well, i'd start this but then got carried away with the rest, and forgot about it. So suddenly i've remember, and almost ripped the top half of the case off in panic, as it was beginning to stick. Always the way hey!!!! Expletives were rapidly coming out my mouth at this point!!!!

So, after pulling the cam out, and the crank out, measuring the gap and realising the shims in had weren't the right side i decided to call it day until i could get to the shop and get the right sized shim!!! So thats why they say do it at the start!!!!! DOH!!

Anyway......im still very please with how its all gone. Had loads of fun so far. Will update as soon as i get time to continue!!!

66split

looks like your having fun and learning lots too Wink

bet you cant wait to hear it running Laughing

good thread, keep us all posted.

Mustard Man

So, after a bit of delay as i didn't have the Shims, i finally managed to seal the case up........twice......

Naturally i managed to get a bit of card stuck in the case the first time, but second time around i had success!!! Woo hooo! Laughing

Case tourqued and now i can start getting the rest on. So excited as i can now make quick progress.

1st - Fuel pump, in she goes, gears fitted, gaskets......andddd, bugger! already stuck. Engine didn't come with studs to bolt the fuel pump on. So already i have to wait and get more bits...... Mad

I can do other things in the mean time, but its still infuriating....arh well, will all be well worth it when its running...... Rolling Eyes

BJ

Don't you just hate that, I just wanna get things finished myself and can't stand the waiting game Cool

I am sure you will, but hey stick with it mate....

Mustard Man

Cheers,

You just wanna be able to start and keep going to you need to stop rather than stopping as you don't have something don't ya.

Don't know why i put fuel pump, i actually meant the oil pump. Must have been getting to me......

Well, i'll come back to the oil pump later i guess. Next is the oil relief valuves, then the cylinders and heads etc.......very exciting that bit!!! Fingers crossed i can get to that bit without having to stop again.

Mustard Man

Ok,

So here's a question for you all, I've put my case together, but something doesn't look quite right.

If i look down from above - (and the picture below will make more sense) the case holes for the valves / pushrods, doesn't seem to line up quite right with the gaps underneath. But im sure this is actually part of the case so there's no way it can be wrong?

Can anyone confirm this is just how it is??

Mustard Man

Ok, So i've had a good days building.

Oil pump studs have now been attained and put on along with the Oil Pump, although im waiting on the cover plate still.

Then i put in the dual relief valves, and next was for the pistons and cylinders. - Exciting bit!!!

So this whole bit took a good few hours, Had to put in all the studs first and tighten them up. They come in different lengths, so had to study loads of engine build pictures to figure out which sizes went where - dodgy hey!

Then getting piston rings in place, compressing them to get the cylinder over, getting to rods in place and sliding it all in to place......

Well, its all on and take a look at the pics to see hows its looking. Getting closer to and engine rather than just a lump of metal!!!

Next i've gotta get some tin into place. Easy. ha!!!
I bought some lite tin, which is better designed for better cooling but can i sit it into place! NO!!!

Anyone else got some of this stuff and sat it in?? Advice would be good here please. Thanks

See pics below!!

Brookie

This should help

http://thekombikonnection.myfreeforum.org/about487.html

Cheers Smile

Mustard Man

Tried this page, but no help sadly. Thanks though.

Brookie

Have you read this and other searches on cool tin

http://newsgroups.derkeiler.com/A...w.aircooled/2005-12/msg00552.html

-----------

BJ

Hey Mustard you have a fancy shed! Or is that your lounge room Rolling Eyes

Sorry I can give any technical help on this one.....It's way over my head

Mustard Man

Ha, its my living room come shed! Very understanding house mates.....

Would love a shed so i can leave it all out and ready to do the next bit, but alas, i don't so have to pack it all up after everytime!

G Mac

I have the aftermarket "cool tin" on my bus also
an had it tie wired to the head/barrel studs
because they do not clip inbetween the studs like they should

......graham

Mustard Man

ha, well thats good to know, it seems to half clip in, but just won't stay there. Maybe a bit of wire is the answer then.

Cheers!

Mustard Man

So, not much happening on the engine build at the mo, Confused

Managed to sort the tin out with a mixture of hammering and wire to stop any potential rattle.......Guessing with the bigger cylinders i've put on, the tin doesn't fit so nice?

Then i've got both my heads on an torqued up and im just cleaning up a second hand pair of rockers i bought to fit on. Have also bought some
swivel foot adjusting screws for the valves. Seemed a clever upgraded but heard mixed things about how much the really help. If it just helps a bit then thats good in my eyes.

Once the rockers are in there's nothing else i can do untill the old Engine comes out so will be on hold over x.mas. Who wants to help? Wink

Im gonna down a trip round the SW over the holiday in Mustard. About 1800k so hoping the engine will hold out for one last big stint! Should be fun.

pic below of head going on and Push rods and tubes. Very satisfying bit this!! Very Happy

Ha....an notice how the milk crate is beginning to sag!! Poor thing.

Mustard Man

Head is on! Missed this pic from last post!

Phat bus

Hey Mustard,

It's been great reading your experience with this build up. Just a few questions that may sound silly unless you forgot them.
Did you lube all the cam lobes with proper cam lube? Your cam will wear out very quicly if you haven't.
Have you checked the crank end play / float?
You know that you have to run a new cam in by making sure the engine keeps reving above 2000 rpm for 20mins on the 1st start up of the motor?
What carby do you intend on using on this new motor? If different to the one your using on your current 1600 motor it might be a good idea to run the new carby on your exisitng motor then change it onto the new motor. This way you should have got the tuning half way right so the new motor starts 1st time.
Anyway, just some food for thought. I'm on holidays now, so if you want a hand just get my contact off Kinga.
Cheers and good luck with it all Smile

Mustard Man

Hi,

Cheers for the comments....Good to hear from ya!

Cams, No Cam lube added....hmmm, didn't get that info on the stuff i had on the engine build.....bit late now. Doh. Guess i'll have to see how it goes..

Have checked the End play....took a while to get sorted but have a lovely. .004 of play left once all the right shims were in.

Got some good info on the first start up of an engine and had read the 2000rpm bit for 20 mins or so.

Looking at putting a set of Twin Kaldrons on, with a Hotdog pipe! Purchases for after X.mas. Then it'll be getting the lads round to help take engine out, swap final parts over and then get the engine back in!!

Can't wait, and will be calling for help for sure.

Deano · Cam Lube

Google, Flat Tappet, you may have second thoughts about cam lube. Choose your engine oil carefully.

Deano

Mustard Man

Hmmmm,

Things to think about there.........Cheers.

Brookie

Hi Rich,
Have made a "sticky" with so many lookers.

-------------------------

Mustard Man

Wooo Hooo!!!

Phat bus

So how is the engine build going?
I guess you've had to strip the motor again to put the cam lube on?

Mustard Man

All good with the build, i just need to figure out a good time to pull the old one out of the Bus and do all the engine bay work, and swap parts over.

Thinking thats gonna take me at least 2 weekends and the week inbetween. Not really 100% sure what it'll involve either. Some parts maybe be perished...all will need cleaning.....tin will need repainting..degreasing...etc......Rust repair.......

Wanna come and help me?? Very Happy

Mustard Man

P.S Yes, stripped the motor again......didn't take long really, just a pig spliting the case, then when you do, all your crank falls out everywhere. I just plastered the Cam Lugs with the stuff........

When would be a good weekend for you? Probs only need 1 afternoon to get it out.....then i can sort the rest out in the week. So any old Sat am your around. Between 3 of us we should be good?

Phat bus

This Sunday is open for me. That way you can have the tin wear powder coated early in the week and have the motor in the next Friday night ready for a cruzie Smile

Mustard Man

Ok,

So 'with a little help from my friends' i've pulled the engine out at last. Stripped most of it down and started cleaning bits up and transfering them across to the new.

Removal wasn't too hard at all. As long as you have one amazing jack to hand. 6 Bolts does most of the work. Then its slips out with amazing ease.

New engine is coming along, with new or cleaned up parts going on all the time. Bay is being cleaned up, tin wear will go off to the sand blasters this week, and with luck the powder coaters too.

When thats back, i can finish builing the engine, with new set of twin carbies....sooo excited!!!

Things were i've got stuck here are the stupid bits like nuts being jammed onto threads, or the huge problem of getting the generater off the fan. That bolt is sooo tight!!! Also managed to thread a bolt on the stud that holds the rocker on, so had to saw that off and will have to replace!!! Arr well. All part of the fun!

So, here are a few pictures along the way! Hopefully the next ones maybe a fully build engine!!!!????

Mustard Man

Thought i'd stick a few pics of how the new engine is coming on. Slowly getting the bits on. Beginning to look the business now!! Very Exciting. I tell ya, i really love this stuff.

Can't wait to start pulling the old one apart and rebuilding that one.

At the mo, im cleaning up all my tin wear, was originally just gonna degrease it all and repaint, but didn't have the tools needed really (a big ass bucket to soak it all in) and found it a never ending process. So, instead im just sanding back to bear metal and painting with high temp. Quicker, easier and better finish too! Now do i go for a crazy colour or just black??? Choices??? Chevy Flame Orange has caught my eye for some reason!! Rolling Eyes

Then tackling the engine bay.....just wanna tidy it up, i not trying to make a show engine.....so clean, degrease and a light spray. Will tackle a rewire at a later date.

Pictures of this stuff 2moro.....oh, and of the major pain in the back side it is replacing the rear Transmission seal behind the throw away berring!!!

Brookie

If it was a show car and not being driven "crazy colours" are OK.
The tinware , firewalls etc in VWs are black for temperature control.

----------------------------------

Mustard Man

Well, Tin wear is almost all done, primed and ready for that final coat. I ache from the sanding, kills the arms......Yes Black is the sensible thing to do, but i've never really followed that line so with my colour advisor (its all about the triangles? Wink

) I've choosen something just a little out there.....its definatly not black.

I've got the fly wheel tourqued.....my god how hard is it to find a 36mm socket??? Used the muir trick of a big bar bolted onto one clutch stud and the wrench. Worked brilliantly. 220 ft pds! no worries.

So now, clutch on.....tin wear on, carbs on, exhaust on, hoses on....and then.....well, then i think i might almost be ready to put in back in and start it up!!! Shocked

The work shop!

The paint shop

VW wind chimes....

Mustard Man

Ok.....gettin really close now!

Engine bay painted, Fuel Tank Cleaned out, Tinwear on, Alternator on, Carbies on, hoses on, oil cooler on, pully wheels etc on, cables on, shiny bits on!! etc. Just a few bits left. And on Saturday its going on! God i hope it starts!!!!!

moo ha ha....i built this!! Love the colour, (cheers Kinga!)

Have some issues along the way.....Couldn't split the Fan from the Genny. Tried everything....or at least everything i had to hand. Had a little help from a man in the know, and it came off really easily??!?!?

Also, Carbies i have and the 40hp Fan Shroud. Well they just werent' made to be together! So had to get the 36hp shround instead which is all good but time, money, hassle etc....

See, the lump in the side just doesn't work....

And further evidence!!!

Anyway.

Whats left. Brake assist hoses...Oil Filter into bay....last few hoses...exhaust on, Holding bar....Errr, and i think thats it. Just to get it in, cables attached im start her up!!!!

Fingers Crossed

Mustard Man

Well, after a long long Saturday the Engine is finally in! Very Happy

Why is it in your head there's only a few jobs to do, but when you start there are always double! arr well. Its in and thats what matters. Laughing

I had two great helpers who without i would've had no chance, so thanks to them, not to mention the fantastic machine work for the oil filter adapter!

Engine in took about 2.5 hours....naturally if it had all gone smoothly could've been 1, but things never go smoothly do they, especailly when you forget to put the accelerator cable through the housing....even after the 5 time??!!! Embarassed

Anyway....few pics of the process....notice the last ones where its almost dark!!!

final building process

Top notch machining from the team!

Up a bit

Down a bit

And its in

fuel lines connected up, oil lines in and oil filter put in place, gear box oil changed....

Tomorrow....Exhaust on, Last piece of tin, Foam in, Connect electrics up, Break breather hose and then.....well then i think i can start her!! WOO HOOOO!!!! Laughing

Although im sure there are another 10 things i've forgotten.. Rolling Eyes

Kinga

Hurry up Rich!!

It's time for the "break-it-in" cruise

Mustard Man

You sure thats not the Break down cruise!!??

VLKSWGN

Top work rich, love the color.... this is one of the best How I Did It threads:D

I can see you liftin up that engine lid at the shows dude Cool

Steve

Mustard Man

Thanks Steve........

Last night i managed to get the Exhaust on, So shiny i love it!!! the lower tin, that sit under the heads, and the rear piece of tin.....

Starter motor is in place too, but here i have a problem. the top bolt on the Starter motor does up with a bolt in the engine bay....now the engine is in and i've an Oil Cooler behind the Fan i can't get to it!!!???? Bit of a nightmare really. Wondering if i can loosen the fan housing and tilt it back and get to it that way but i really don't want to be undoing things. Im meant to be doing things up!!

Tonight....I'll figure something out.

Jobs left.
1. Starter Motor Bolt!
2. Foam in place
3. Oil in
4. Wire up all electrics.....not that i remember when any of it goes!!!
5. Start it up

Mustard Man

Just for anyone thinking of doing something like this!

Dont' do it on your daily driver!

Don't get me wrong, i've loved the whole thing, but i just wanna be able to drive again....but instead every breathing minute im having to work on it...every night when i get home, every weekend etc......which is great, but at the same time, if you want some time off you just can't as you need your car back.

Also, you realise you need some more tube, or tool, or anything, you can't just pop out and get it now can you, so you have to organise someone to get it for you, or get a lift etc. Nightmare!

Means you don't enjoy the whole thing as much as you should if that makes sense......numerous times i've threatened to sell the bloody thing as soon as its finished....which of course i wont! but you understand what i mean.

Its all quite emotional at times really!

Anyway. Thanks steve.....nice to hear the positive words!! I've also been very lucky to have help from a few people that have collected bits i needed or tools etc.....so many thanks to them too.

Keith D

Hey Rich,

As soon as you're driving the Kombi and looking distainfully down on lesser beings in their Holdens, Falcons etc, you'll forget all the trials and tribulations you've been through! You'll just be glad you did all that work! Very well done!

Keith

Aaron.fabs · Engine

Hi Musterd man your a braver man than me luv your work
Aaron

Mustard Man

Quick update,

Foam in place, electrics wired up...although still unsure what to do with the Regulator issue. Oil in.

So, sort the last engine bolt - job for tonight, then fire her up!! Will see how the altenator works and if charges, and figure out what to do with reg after!

Soooooooo close! Hoping to be able to make it to Alfred 2moro!!

Mustard Man

Keith,

Thanks, your right i know...its just getting there. Can't wait to be able to look back at the work and smile while im driving along again.

BJ

Hey Mustard after just looking at the last few pages of this thread I have a smile on me dial......that engine is looking tops mate.

Great work. Your probably in your engine bay or under your bus right now trying desperately trying to get that last bolt in, so you can drive to Alfreds in it tomorrow night.....Bloody dead lines!

I can guess that (I have been there) and not trying to push any bad luck your way, but I can picture the bolt will be a right sod and take hours, then you'll be tuning and adjusting carbs, then you'll here a noise (a new one) and check for that..sit back and enjoy that sound, turnit off and start it again, sit back a rev it a bit, sit back and admire all your hard work then you'll tidy up your tools and realise it's 11:30pm..... Twisted Evil

Another late night

And that's if it all goes smoothly Rolling Eyes

Best of luck in accomplishing your goal soon, nice work!!! ANd I'll see you and it tomorrow Wink

Kinga

Mustard Man

Arh the joys on being so close to the finishing line and stumbling across a huge brick wall.

Well, was dark last night by the time i'd figured out for sure what was needed. And as Kinga described, a fair old wack needs to be removed to solve this.....so raise a buger to me tonight for i'll be working away! Smile

BJ, cheers for the comments, i get a good old smile on my face too looking through the posts. Reminds you what you've achived etc so yeah, all these problems will just make it all the better when i fist start her up and start making her run just right!

Mustard Man

Looking at the below pic, you can see where the top left bolt would go through the engine, and where that sits in relation to the Oil Cooler!! Not a chance in hell in getting to that sucker hey!

Why that one doesn't have a thread on it beats the hell out of me. We were wondering if it was weaker than the otherside (which is threaded) due to the starter motor maybe??

Mustard Man · IT STARTS!!!!!!

Well, it starts!!! Woo hooo!!!!

The Key went in, turned 1 notch and lights came on!! Another and its ticking over. Good start........however, the Oil Pressure light never turned off? Ticked over for about 30 seconds where i decided it was never gonna turn off. checked connections, all seemed fine, tried again, still the same.

So there's an issue with the wire or the sensor. Im sure the pressure is now up and oil pumped round. Although is there a way i can test???

So i decided to actually start it up. Coil connected, plugs in and i went for it. Took a while to get going, slowly the coughs happened, then a splutter and then! Oh yeah! then it started! Got a real growl to it now too. However, (yes another one) it wouldn't stay ticking over on its own, so will have to start tuning the carbs up and setting the idle. Guessing this is the reason. It was dark by this point though so will leave for another day.

Problems though, Genny light still on and Oil pressure light still on, even when it was started. Guessing something in my electric link up is off?

Also, felt a lot of heat coming from the case and items....but the oil itself was still cool.

Is this just how it is with a new engine and will settle after a bit etc, or something i should watch for etc.

Quick history on last few days

Spent the last few night trying to do the math on my Compression Ratio to be sure all is ok. Few the measurements i made i came out with an 8.5 CR, which is fine. (Details - Bore 92mm, Stroke 69mm, DH 1.859mm, Jug CCs 48.5)

Anyone out there good at tuning Carbs and fancy helping me out here? Im sure i can make it worth your while. Would love to be able to get it to the Show on Sunday!!!!

Keith D

Rich,

The oil light staying on worries me.

I am not familiar with your engine, but I would be thinking of removing the oil pressure sensor switch and cranking the engine over with the high tension lead between coil and distributer disconnected, There should be enough pressure from the oil pump to at least ooze oil out of the hole. My engine is the 1600cc and that should run at between 28 and 42 psi. According to my workshop manual, the oil light should come on between 2 - 6 psi, which is a very low oil pressure. This also means that the light should go out when 6 psi is reached. Check these figures in the manual for your engine.
(psi = pounds per square inch)

I am not an expert on VW engines, but certainly on BMC motors you have to prime the oil pump when you've just done a complete rebuild. Maybe Brookie or one of the other VW engine gurus could come in on this one!

Obviously you will need to sort out the genny light staying on, but this is not liable to harm the engine. No oil pressure will DEFINITELY cause severe damage if you keep the engine running.

Keith

Mustard Man

Thanks for the info Keith,

Will try the test with the oil presure switch and see what i get. I do get a 'tsss' sound from the oil filter when i turn the engine off, so i know that there is some pressure moving around the engine and getting to the oil filter. But still would like some more proof.

Not worried about the genny light at the mo, thats easier to fix im sure, and not so serious.

In Adelaide and Sydney for work the next few days so will get back to it when i return.

Brookie

Are you using a stock oil pump? How much extra oil do your lines and filter take?
If you are getting a sshhing noise you may still have air somewhere in oil circuit.

-------------------

Mustard Man

So, Update.

Sender Gauge is fine, used a test lamp and light goes off as after a few cranks, so will have to check my electrics. Also removed the sender and had oil pump out at a good presure.

Oil Pump is a Heavy Duty one by the was Brookie....as i have fairly long oil lines.

Tuned the Carbs so they run nice at idle, and sorted the timing etc...but still getting a fair bit of miss firing going on....although i do have the mixture a bit rich still so maybe because of this. Will get them tuned and sync'd properly once its up and going properly.

Getting a leak out of the Oil Filter when running at the mo, so either a fitment issue, or its stuggling to pump oil out of filter and to the cooler, maybe a gravity thing? Will investige over next few nights.

Closer and closer i get!

Mustard Man

So....after sorting the leak, and doing a final check on everything, etc. Including a compression test - 135psi. Bit high but ok i was ready for the final run in and then all would be finished.

Started it up, coughed a bit and then it died, dead, nothing, just the click of the started motor.

Probs something horrendous has happened inside and seized everything.

Gutted! Crying or Very sad

Keith D

Hey Rich,

Don't despair! Check your battery connections first off! Then if that doesn't fix it you must work out if it is fuel or electrics. Has to be one or the other!

Always expect teething troubles whenever you strip a motor down and completely rebuild it. This is normal! Keep cheerful and smiling. You'll get it fixed!

Keith

Kinga

Phat bus

Hey Rich,

you have discovered a few big positives that are a must before starting a new engine.
1) you have some oil pressure which will almost instantly kill a new motor without it ie no oil = motor death.
2) your compression is 135psi and is the same as mine which is about 8:1 compression ratio. This shouldn't be too high that your motor over heats (unless your rings are not sealing properly or something. But lets be positive here).

You have some back firing which could be carby tune or it can be spark (either timing or ratic spark timing etc). This is just an idea of mine and might be worth checking ok? You have an electronic ignition install now which, yes, worked fine with your old motor. But you have changed the charging system ie now have an alternator and something wired on that side of things is a bit suss because of your oil and ignition lights staying on. So consider this for a moment. I had a Mallory electronic ignition in my bus for 2 years and then one day it stated to back firer and miss. In the days leading up to this I noticed at night my lights were glowing a lot brighter than normal which I only found out after, when my distributor was causing a back fire, that the regulator had failed and the alternator was overcharging. Hence lights glowing bright. But I also learned that electronic ignitions (specially the more expensive ones like a complete distributor change out type) are fairly voltage sensitive and if the voltage supply to it becomes too high or fairly low then the ignition starts to misfire and this can be to the point where the car just won't run.
So do you know where the regulator is for that new alternator that you've installed? Because I know someone has said to you it's an internal one inside the alternator. But I'm wondering if it has one at all and this could be just charging your battery to the full out put of the alternator. Hence, causing the whole miss & back fire problem as well as the ignition light staying on etc.

Anyway, I'd look into it further and see what you find.

Cheers

Phat bus

BJ

Hows things Mustard? I hope this pause between posts isn't a bad sign mate...

Your probably out drivin the bus and havin fun - so you haven't got time to come on here now Rolling Eyes

Fingers crossed for ya

Mustard Man

BJ hi,

Just having a bit of time off from the Kombi, Became a bit of a chore if your with me. Will be back on it soon full of enthusiasm!

Matt, your right, there are lots of positives....i just need to do some investigation. Could be something as simple as the starter moter. Or maybe i'll need to pull the engine out again and have a tweek with the insides. No probs either way!

Will update when i get somewhere!

Brookie

BJ

Hey Mustard Steve is having the same problem with his motor at the mo

He gets the clicking and no turn over thing too. Might be your starter - Is it a newie?

Phat bus

Clicking sound of the starter motor is fairly common when the battery voltage gets down too low. Try recharging the battery if it hasn't been charged just been sitting while you been doing the engine swap.

Mustard Man

Hi all,

Thanks for the thoughts,

Battery shows good charge, and doesnt' drag to much when i try and start it, All lights stay bright etc.....which makes me believe its not that!

Also, i can't turn the motor by hand, which is the big worry. Wondering if the Starter is locked in and thats the problem?

So, im trying the battery out the car to see if that works......
Then im taking the Starter Motor out, and seeing if it spins by shorting it. At the mo it doesn't spin when i short it, just clicks still.

If the starter spins, now, with luck the Engine will be able to be turned over too? If not......something inside had gone wrong.

In which case, i'll take it to the shop, and get an expert to take a look and sort it. They can also do the final tuning to it too, and then i can drive it home all sorted! Smile

Brookie

Put in 3rd gear and gently try rocking Kombi backwards and forwards- this will usually "pop" a locked pinion gear free.
Is it the correct pinion for ring gear?

------------------------

Mustard Man

Brookie,

Tried the 3rd gear trick but no joy there. Took the starter out, and it ran free when i shorted it, but still the engine didn't turn.

Arr well! Confused

Mustard Man

So,

The latest.......after trying and failing to figure an easy way to sort my problem and get the engine going again i decided to hand it over the experts.

ASAP the engine will be going to the shop to be checked over, put back together and tuned up, ready to be installed straight back in to the kombi. That way i can be sure thats it's all good, will last and not worry about every knock and bang.

Its a shame to have to hand it over to someone else, as i loose it bit of the satisfaction of doing it myself, but the knowledge and enjoyment i gained from building it will serve me well. I really did enjoy it, and learnt soo much!

Fingers crossed my next update will be after my first drive! Very Happy

liam:-)

yeah mate if u have the skills and time to get it that far (which is bloody impressive) im sure some final paid work wont take much of the edge off that achievment Very Happy

she looks beautiful now!

Mustard Man

Hi all,

Been a while, bu the engine is back from the shop and ready to be fitted! So good to have it back, but feel bad that i haven't done much on the kombi in the last 3 months. Would've been a great oppotunity to work on other bits. Money limits though!

Anyway. Fingers crossed it'll be fitted and working soon!

Richard & Mustards Engine Build

Engine Build Update

Cam shaft in

I missed something

Cam Lube

Engine

IT STARTS!!!!!!