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A tired looking VW 1600 engine ready for transformation. First stage, strip it and discard the fan belt, S/P leads, fuel hose and any other perishable items. |
Complete strip down begins. Note the serious coking on the pistons. Some specialists suggest a light clean, leaving a coating of coke. For me...it's ALL off. |
The cylinders are checked for scouring, excessive wear (int. dia) then cleaned and honed. Over size rings must be used for the re-build if not using a new cylinder kit. (Refer DIY Guide) |
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The heads are in need of some work. Check for cracked valves, bent valve stems and serious wear around the valve seating area. (Refer DIY Guide) |
The heads after a port & polish. No broken or cracked cooling fins and the valves have been re-seated. Be careful not to break through the exhaust port walls when de-coking. |
The valve train before and after refurbishing. Fairly straight forward process. Check for excessive wear points. |
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The fully assembled heads are now fitted with care ensuring that all studs and nuts are tensioned to specifications. (Refer DIY Guide) |
Slowly the power plant is restored. Of extreme importance is ensuring the main shaft end-play is set correctly. Usually .004" (0.1mm)+/- .001 |
Finally all done and dressed up ready to go. The pink lampshade got tossed. (Refer DIY Guide) |
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