kevino
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Post by kevino on Jun 21, 2023 11:11:22 GMT -5
Just to put a little light on the situation, I took off the plastic on the sides of seat. That helped see the three holes. Two small and one large. Spinning the flywheel by hand I can't get the TDC mark to like up with anything. I wonder if it's hidden by dirt.
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kevino
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Post by kevino on Jun 21, 2023 11:14:30 GMT -5
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kevino
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Post by kevino on Jun 21, 2023 11:20:53 GMT -5
Taking off the chain tensioner and nuts I put them on the last clean corner of the work table.
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kevino
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Post by kevino on Jun 21, 2023 11:34:35 GMT -5
I just realized the metal plate embedded into the plastic flywheel is a magnet. That makes it part of the CD!. Rotating clockwise the plate comes into view then shortly the F mark followed by the T mark for TDC.
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kevino
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Post by kevino on Jun 22, 2023 6:40:03 GMT -5
   Okay, I'm ready TO pull the the two chain tensioners and lift the can out. But I still can't find TDC on the engine case. There are two 8mm bolts in the corners 2A . 6. It feels like TDC is between the two but there's no mark. Even the Haynes manual on page 2A.6 shows a nice photo of the ridge with an arrow pointing to it. But I can't find that ridge. With the can showing all 3 holes there's no mark on the flywheel. I have to rotate it clockwise and then the magnet and F ant T marks come up. In a car this would be easy. Start cranking it while turning the distributer. Ultimately it fires or at least back-fires. That tells me I'm close but this motor has no distributer?  ? |
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kevino
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Post by kevino on Jun 22, 2023 11:01:25 GMT -5
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kevino
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Post by kevino on Jun 22, 2023 11:05:32 GMT -5
Okay, I found the TDC mark. For the last two photos I set the cam so the three holes were visible. Then walked around to the other side. The metal plate was highest but I looked to the left side and saw the T even with an obvious mark in the body. The second photo shows that clearly. Thanks for all the help.
kevin
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kevino
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Post by kevino on Jun 22, 2023 14:03:30 GMT -5
Everything is out that had to be removed. Tomorrow I start trying to put it all back together.
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kevino
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Post by kevino on Jun 23, 2023 7:06:00 GMT -5
Over the years (decades) I've done more than a dozen ring-and-valve jobs on VW beetles but also one Ford F150, one Datsun B210, a Jeep Grand Wagoneer and several motorcycles from 100cc to 750cc. I'm worried because the BBK piston is sooooo small compared to the cars I've had. What is the chance I'll break the one or both of the oil rings while trying to get them installed with the third groove?
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kevino
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Post by kevino on Jun 23, 2023 9:37:29 GMT -5
The rings are in. BUT...the circlips are impossible to use. What is the point of the odd shape? I spent hours trying to get one circlip seated in the piston. Technically I spent hours looking for a circlip that had sprung free and migrated to the other end of the garage. Multiple times. I've got old surgical tools that might hold the clip better than the needle-nosed pliers I used on several engines.
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kevino
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Post by kevino on Jun 23, 2023 10:54:09 GMT -5
 Okay the circlips yielded and the piston is in. It slides down fine. It hits a stopping point and goes nor further. The chain isn't binding. I don't want to use a hammer to force the piston further along. Any suggestions? TIA, kevin |
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Post by 90GTVert on Jun 23, 2023 11:17:12 GMT -5
Okay the circlips yielded and the piston is in. It slides down fine. It hits a stopping point and goes nor further. The chain isn't binding. I don't want to use a hammer to force the piston further along. Any suggestions? If all of the rings are in and it moved a bit and then stopped, I'd want to know if the piston skirt is hitting something. |
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kevino
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Post by kevino on Jun 23, 2023 11:54:59 GMT -5
I thought about that so I pulled the cylinder out and checked. No signs of anything wrong. No binding or signs of the chain being stuck. I found a spacer I didn't know I'd lost. I put two spacers in the cylinder. They don't seem to be binding. I've been moving the flywheel back and forth and no signs of a problem. The kit came with a new metal gasket. It only goes in one way. Frustrating!
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kevino
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Post by kevino on Jun 23, 2023 13:24:03 GMT -5
I found the problem. The metal gasket goes between the cylinder and the head. I found a paper gasket in the kit that goes between the cylinder and the body. I quit for the day after getting the cylinder mated to the crankcase body.
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Post by geoffh on Jun 23, 2023 15:48:55 GMT -5
Pesky pin clips  I used a pair of needle nosed pliers with a groove cut close to the end to help and a piece of string through the pin to catch the little blighters as they escape . Worth saying make doubly sure they seated properly,I lost two cylinders and many many hours of searching to these clips.my therapist says I should "share". Geoff |
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I used a pair of needle nosed pliers with a groove cut close to the end to help and a piece of string through the pin to catch the little blighters as they escape