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I pulled the intake valve....very bend and as Wil suspected very carbon-ed up

New valves is...it took all my strenght to NOT clean up the port, not ever the massive ridges at the base of the seats.

Quick de-carbon the pistons

Head on. Progress.

The VW is no longer busted and seems to run fine again. I just need to put on a couple covers and kick it out of the shop

Mark, simply amazing the way you've knocked out this project with everything else on your plate AND a normal day job!

But.....be aware your energy level really starts dropping off after the big 50 At least in my case it did.

Things go faster when the project is standing between me and finishing the ferrari:)

Its not done though

It runs fine but I noticed the damper is wobbling.....its got a weird mount and something's just not right. I noticed it when I pulled the car out into the daylight to check for leaks. Maybe I can just beat it straight or I need a new one.

Keyed to go on only one way? So the balance weights and the timing notch will be correct?

Yes, it's keyed by the tooth pattern.....but it's a face mount so prone to run-out or wobble issues....which I fixed with a hammer yesterday

with the wobble mostly gone I drove it around a bit and it's not quite right. Its a little slow starting and doesn't pull very hard past 4000-4500 and is throwing a code for cam/crank position mismatch so all signs point to me having a cam timing issue....something must have moved and it's not so easy to check since there are no actual timing marks in the conventional sense. This engine has marks on the cams/crank and marked links on the chain and you can't see the bottom chain mark without pulling a lot of stuff apart so this is going to turn into a protractor on the drawing job

Yup, it looks like it skipped a tooth while I was clamping everything down

Hopefully I can skip it back.

Can't you hire the cam timing tools for it?
It shall certainly make your life easier.........not that you are one for easy.

That's the thing...there are no tools or I would have bought them. There are marks on the gears and chain and you line them up....in theory it's simple but remember I started the thread with:



and I meant it.


Yesterday I found the VW document that's attached...simple right?

but the cam gears don't match the picture exactly, the intake in particular so I'm just kind of guessing I found the right mark. The repair manual I bought said rotate the crack to align the TCD mark and pointed to a mark that was very clearly NOT TDC ( I had the head off) so I used the the other mark I found which was TDC. OK so far.

With the crank in that position I couldn't see the little triangle on the timing gear but the triangle to key the damper was exactly where the picture shows so I assumed that was the indicator for my engine.....but something just din't look right when I was looking at the cams.....but the marks are the marks so I put it together and made sure there was no resistance anywhere....and it ran but rougher than I recalled??????

Last night I put the crank where the VW pic shows (NOT TDC!!!)and sure enough there is a triangle on the crank pulley...like 100 degrees from the mark I used on round 1 assembly so now I'm trying to understand how the heck the engine ran with the cams about 100 degrees out of time????? That seems impossible so now I'm wondering if I've found the right marks on the cam?????

normally I'd put a degree wheel on and make god damn sure.....but the cam cover IS the cam caps so you can't have the cover off and cams installed.

I hate this engine.

Oh, I forgot this part. Now that I've found what I think is the correct timing mark for the chain on the crank....it doesn't appear to be centered on the link like it should be. It appears to be one end or the other end of the link, at least from where I'm looking so maybe it's just parallax and I need to get a mirror in there.


But I still don' see how the hell it was running 3/4 good if the cams were actually 100 degrees out of time?