My ABF Rebuild thread...THE NOOB WAY-UPDATED JULY (no 56k)
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My ABF Rebuild thread...THE NOOB WAY-UPDATED JULY (no 56k)
Hey guys, its update time…
I managed to source another block from a friend, I will be getting it within the next week or so, I will be swapping all my internals over to the new one.
block stripped, well almost:
before i touched the head, after removing the inlet mani:
So I stripped the tappet cover off, what a mission as the countersunk nut was rusted from the water sitting in the hole for so long, I had to drill the mofo out carefully, what a mission!!
What was left of the stud:
this is what the internals looked like
cams code
being a noob, i marked everything hahaha, just to make sure if it may help me out at a later stage, i will be replacing the cam chain, but market it anyway- funny, the original part is Febi?
oh, where can i get another distributor thing? mine is cracked as you can see:
i removed my first cam cap
any advice on removing these? as you can see, mine are really rusted and i have soaked them in penetrating lube! the problem is that my ratchet/spanner slips on the nut due to the rust! is it a costly thing to have the studs replaced? i may have to grind the nuts off before sending it away to 8V performance?
cams out, do they still look good to you experienced guys?
lifters still look good?:
and a mind fcuking shot lol
soooo...i took the plunge and removed the head bolts in order, bit by bit until they all came out:
whooped off the head pistons look good
this little baby, no. 4 had some extra carbon on, any need for concern?
there was some oil that came out, duno if it came from the head? is this normal, only in two places though;
hone marks:
the valves:
im posting one pic of the combustion chamber, they were all pretty much the same:
I managed to source another block from a friend, I will be getting it within the next week or so, I will be swapping all my internals over to the new one.
block stripped, well almost:
before i touched the head, after removing the inlet mani:
So I stripped the tappet cover off, what a mission as the countersunk nut was rusted from the water sitting in the hole for so long, I had to drill the mofo out carefully, what a mission!!
What was left of the stud:
this is what the internals looked like
cams code
being a noob, i marked everything hahaha, just to make sure if it may help me out at a later stage, i will be replacing the cam chain, but market it anyway- funny, the original part is Febi?
oh, where can i get another distributor thing? mine is cracked as you can see:
i removed my first cam cap
any advice on removing these? as you can see, mine are really rusted and i have soaked them in penetrating lube! the problem is that my ratchet/spanner slips on the nut due to the rust! is it a costly thing to have the studs replaced? i may have to grind the nuts off before sending it away to 8V performance?
cams out, do they still look good to you experienced guys?
lifters still look good?:
and a mind fcuking shot lol
soooo...i took the plunge and removed the head bolts in order, bit by bit until they all came out:
whooped off the head pistons look good
this little baby, no. 4 had some extra carbon on, any need for concern?
there was some oil that came out, duno if it came from the head? is this normal, only in two places though;
hone marks:
the valves:
im posting one pic of the combustion chamber, they were all pretty much the same:
Last edited by bru-tom on Fri Jul 02, 2010 12:12 pm, edited 1 time in total.
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
The exhaust studs on the head are cheap, im sure sarel can replace them for you. You need the leave the cams in the head when sending it to sarel, he can also replace the cam chain for you.
2006 E92 335i * Monica
2001 Audi S3 Quattro * Suzie-Q
1999 Jetta 3 20vt 181kw 390nm * Jet-Li
2006 Caddy 1.6 low and slow * Tossa-Caddy
2001 Polo classic 16v ABF Featured * BLUEmotion
1988 Bmw E30 2.9L - Written off
1991 MKII GTI - Sold
1989 MKII CSL - Sold
2001 Audi S3 Quattro * Suzie-Q
1999 Jetta 3 20vt 181kw 390nm * Jet-Li
2006 Caddy 1.6 low and slow * Tossa-Caddy
2001 Polo classic 16v ABF Featured * BLUEmotion
1988 Bmw E30 2.9L - Written off
1991 MKII GTI - Sold
1989 MKII CSL - Sold
Saiendra wrote: I cannot argue with you, you bought a BMW out of motorplan...
You clearly have more balls than me.
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
thanks Shaun! do i need to torque them up again? i dont want them to snap with the transporting...SHAUN wrote:The exhaust studs on the head are cheap, im sure sarel can replace them for you. You need the leave the cams in the head when sending it to sarel, he can also replace the cam chain for you.
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'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
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'A Trend is For a Month, Style is Forever...'
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
No need to torque them up, just fit them back without the chain and ask sarel to fit a new chain for you, he likes to check all the clearances with the cams fitted once the job is done to make sure everything is 100%.
2006 E92 335i * Monica
2001 Audi S3 Quattro * Suzie-Q
1999 Jetta 3 20vt 181kw 390nm * Jet-Li
2006 Caddy 1.6 low and slow * Tossa-Caddy
2001 Polo classic 16v ABF Featured * BLUEmotion
1988 Bmw E30 2.9L - Written off
1991 MKII GTI - Sold
1989 MKII CSL - Sold
2001 Audi S3 Quattro * Suzie-Q
1999 Jetta 3 20vt 181kw 390nm * Jet-Li
2006 Caddy 1.6 low and slow * Tossa-Caddy
2001 Polo classic 16v ABF Featured * BLUEmotion
1988 Bmw E30 2.9L - Written off
1991 MKII GTI - Sold
1989 MKII CSL - Sold
Saiendra wrote: I cannot argue with you, you bought a BMW out of motorplan...
You clearly have more balls than me.
- panic-mechanic
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
Just leave it as it is - He's got to take it apart to do the work anyway. Just make sure you send all the bits with so he can assemble it again.
Stephan van Tonder - Jhb - Putfontein Benoni
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
Howsit Bru-tom
With those exhaust studs, try using a vice grip to open them or grind them off or try knocking another smaller socket over it. Studs are relatively easy to replace. You have your work cut out. Good luck
With those exhaust studs, try using a vice grip to open them or grind them off or try knocking another smaller socket over it. Studs are relatively easy to replace. You have your work cut out. Good luck
Have you had your bottle of Hatorade today?
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
SHAUN wrote:No need to torque them up, just fit them back without the chain and ask sarel to fit a new chain for you, he likes to check all the clearances with the cams fitted once the job is done to make sure everything is 100%.
that's what i like to hear! im looking more and more forward to spending 3k lol
thanks Stephan...i will leave it as is and leave the cams, etc in the head with the caps finger tightened...must i also send the distributor and cam pulley?panic-mechanic wrote:Just leave it as it is - He's got to take it apart to do the work anyway. Just make sure you send all the bits with so he can assemble it again.
thanks dude, i dont think i am going to wreck another socket lol, broke an el' cheapo trying to get an allen cap screw out of the breaker thing on the block alreadyVWicked wrote:Howsit Bru-tom
With those exhaust studs, try using a vice grip to open them or grind them off or try knocking another smaller socket over it. Studs are relatively easy to replace. You have your work cut out. Good luck
i like the grinding route at this stage hahaha
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'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
Cam pulley yes, dizzy now.bru-tom wrote:thanks Stephan...i will leave it as is and leave the cams, etc in the head with the caps finger tightened...must i also send the distributor and cam pulley?
You only doing the head? i had my inlet manifold and throttle body done by sarel aswell.
2006 E92 335i * Monica
2001 Audi S3 Quattro * Suzie-Q
1999 Jetta 3 20vt 181kw 390nm * Jet-Li
2006 Caddy 1.6 low and slow * Tossa-Caddy
2001 Polo classic 16v ABF Featured * BLUEmotion
1988 Bmw E30 2.9L - Written off
1991 MKII GTI - Sold
1989 MKII CSL - Sold
2001 Audi S3 Quattro * Suzie-Q
1999 Jetta 3 20vt 181kw 390nm * Jet-Li
2006 Caddy 1.6 low and slow * Tossa-Caddy
2001 Polo classic 16v ABF Featured * BLUEmotion
1988 Bmw E30 2.9L - Written off
1991 MKII GTI - Sold
1989 MKII CSL - Sold
Saiendra wrote: I cannot argue with you, you bought a BMW out of motorplan...
You clearly have more balls than me.
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
thanks man...SHAUN wrote:Cam pulley yes, dizzy now.bru-tom wrote:thanks Stephan...i will leave it as is and leave the cams, etc in the head with the caps finger tightened...must i also send the distributor and cam pulley?
You only doing the head? i had my inlet manifold and throttle body done by sarel aswell.
i think i must send the mani, only the bottom part right? i will be running diktator, can i use my OBD2 with it? iv had it for a long time already, pointless to let it go to waste
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
Diy is bestest bru. Goodluck with the build.
Send the whole manifold for polishing. As for that dizzy cap im pretty sure they are the same for all the 16v heads so just look around. The obd2 tb will work but if you not running mp9 theres no need stock one will be fine.
Send the whole manifold for polishing. As for that dizzy cap im pretty sure they are the same for all the 16v heads so just look around. The obd2 tb will work but if you not running mp9 theres no need stock one will be fine.
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
Oops - sorry no - The last bearing of the cam runs on the one side of that cap and cylinder heads are individually line bored so they are unique to each head. You can find another but then you have the have all the caps line bored.As for that dizzy cap im pretty sure they are the same for all the 16v heads so just look around
Stephan van Tonder - Jhb - Putfontein Benoni
'05 Audi A6 3.0L TDI Avant
'09 Touareg 3l TDI
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'05 Touareg v10
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'05 Audi A6 3.0L TDI Avant
'09 Touareg 3l TDI
'13 VW CC 2l tdi (repair project)
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Perfect Power dealer. I do dyno tuning.
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
Damn. Sorry bro wasnt thinking right. I got lost in thought by wat colour the dizzy seal was. Panic is right if you replace you need to line bore.
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
thanks man, i will and am doing my bestestKillerwatt wrote:Diy is bestest bru. Goodluck with the build.
Send the whole manifold for polishing. As for that dizzy cap im pretty sure they are the same for all the 16v heads so just look around. The obd2 tb will work but if you not running mp9 theres no need stock one will be fine.
the whole manifold? top and bottom? but can i use the obd2 anyway?
what does this mean exactly Stephan?panic-mechanic wrote:Oops - sorry no - The last bearing of the cam runs on the one side of that cap and cylinder heads are individually line bored so they are unique to each head. You can find another but then you have the have all the caps line bored.As for that dizzy cap im pretty sure they are the same for all the 16v heads so just look around
is the pic below the line bore in the cap? or is it the slit in the end of the cam that the dizzy runs off?
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'A Trend is For a Month, Style is Forever...'
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
Line boring is an engineering process where you make a straight perfectly aligned hole through an item.
So in the factory after a head is cast they first of all engineer a flat surface on the back side of the head. Then they will add the cam caps in rough cast to the top. Then they take a line bore machine and cut the holes for the cam through the head and the caps. This is done to each head and the position might vary very slightly from one machine to another. If you now take a cap off another head and install it on your head the hole through which the cam runs that basically is also the bearing surfaces might be very slightly misaligned. If you now tighten theis cap it will eaither crack the cap or bite the cam. if you manage to turn the cam it might seize after a while on that bearing surface. So now if you find another cap that didn't belong on that head you have to take the head and caps to an engineering shop - they will skim a small area off the bottom of all thecaps - this now makes the hole to small and slightly oval. They then repeat the line boring process which opens all the holes perfectly and now the caps and cam will fit again perfectly.
So in the factory after a head is cast they first of all engineer a flat surface on the back side of the head. Then they will add the cam caps in rough cast to the top. Then they take a line bore machine and cut the holes for the cam through the head and the caps. This is done to each head and the position might vary very slightly from one machine to another. If you now take a cap off another head and install it on your head the hole through which the cam runs that basically is also the bearing surfaces might be very slightly misaligned. If you now tighten theis cap it will eaither crack the cap or bite the cam. if you manage to turn the cam it might seize after a while on that bearing surface. So now if you find another cap that didn't belong on that head you have to take the head and caps to an engineering shop - they will skim a small area off the bottom of all thecaps - this now makes the hole to small and slightly oval. They then repeat the line boring process which opens all the holes perfectly and now the caps and cam will fit again perfectly.
Stephan van Tonder - Jhb - Putfontein Benoni
'05 Audi A6 3.0L TDI Avant
'09 Touareg 3l TDI
'13 VW CC 2l tdi (repair project)
'05 Touareg v10
Perfect Power dealer. I do dyno tuning.
'05 Audi A6 3.0L TDI Avant
'09 Touareg 3l TDI
'13 VW CC 2l tdi (repair project)
'05 Touareg v10
Perfect Power dealer. I do dyno tuning.
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
thank you kindly Stephan, always willing to share your knowledge!panic-mechanic wrote:Line boring is an engineering process where you make a straight perfectly aligned hole through an item.
So in the factory after a head is cast they first of all engineer a flat surface on the back side of the head. Then they will add the cam caps in rough cast to the top. Then they take a line bore machine and cut the holes for the cam through the head and the caps. This is done to each head and the position might vary very slightly from one machine to another. If you now take a cap off another head and install it on your head the hole through which the cam runs that basically is also the bearing surfaces might be very slightly misaligned. If you now tighten theis cap it will eaither crack the cap or bite the cam. if you manage to turn the cam it might seize after a while on that bearing surface. So now if you find another cap that didn't belong on that head you have to take the head and caps to an engineering shop - they will skim a small area off the bottom of all thecaps - this now makes the hole to small and slightly oval. They then repeat the line boring process which opens all the holes perfectly and now the caps and cam will fit again perfectly.
i think, what i should do is, have it alli welded,its not completely snapped off, just cracked...
see, once again:
hopefully if done quickly and spot on, it wont heat up the entire thing too much that will make it warp the bearing...
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'A Trend is For a Month, Style is Forever...'
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
ok, engine update...
got my head back after some flow and 3 angle valve work, dont know what i should be looking for to see if its been done great or not, maybe you guys can help me with that
pics of head:
lower intake, port matched and flowed:
and the TB:
some OEM parts that i wouldn't trust buying from anyone else but agents:
new INA lifters, VR head gasket and ACL Race big-ends:
random:
still waiting for a tow gasket/seal set and bottom end seal set, ACL mains and Cofap rings + waterpump
block is getting worked and ballanced as we speak... and ARP rod bolts coming soon too
bought an OEM 16v oilpump from Meox (thanks Liam)
things are coming together nicely now
got my head back after some flow and 3 angle valve work, dont know what i should be looking for to see if its been done great or not, maybe you guys can help me with that
pics of head:
lower intake, port matched and flowed:
and the TB:
some OEM parts that i wouldn't trust buying from anyone else but agents:
new INA lifters, VR head gasket and ACL Race big-ends:
random:
still waiting for a tow gasket/seal set and bottom end seal set, ACL mains and Cofap rings + waterpump
block is getting worked and ballanced as we speak... and ARP rod bolts coming soon too
bought an OEM 16v oilpump from Meox (thanks Liam)
things are coming together nicely now
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'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
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'A Trend is For a Month, Style is Forever...'
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**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
I have all my bits to start the assembly process, just have to get the block painted and clearances checked.
so my blocks old sleeves were hacked out, new ones fitted to standard size. i was very nervous to do the whole re-sleeve thing, but i dont have 6k for 20thou oversized ABF pistons laying around lol:
they were bored and honed, block had a slight skim:
new brass plugs to go in here:
crank has been polished:
and pistons cleaned up nicely:
till next time
so my blocks old sleeves were hacked out, new ones fitted to standard size. i was very nervous to do the whole re-sleeve thing, but i dont have 6k for 20thou oversized ABF pistons laying around lol:
they were bored and honed, block had a slight skim:
new brass plugs to go in here:
crank has been polished:
and pistons cleaned up nicely:
till next time
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'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
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'A Trend is For a Month, Style is Forever...'
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**My 77' HONDA CB550 Project**
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
ok, so after a long wait, my block is ready to go home! now for the rest of the bits to be assembled onto the sub assy
so my crank was polished and ballanced:
rods and pistons weighed and ballanced, also fitted ARP rod bolts
test fitted mains and big ends to check tollerences, everything measured perfect! then came fitting crank and torquing everything up:
lightened and ballanced intermediate shaft
first we checked the clearance where the rings come together to make sure they are all the same- 0.25mm
then came fitting cofap rings:
compressing rings:
one more to do:
fitting piston into cylinder:
and voila!
all big ends torqued up to spec with ARP special lube- thanks Trippy!!!!!
we also measured the deck height of the piston on each cylinder and they all measure 0.55mm above the surface of the block! awesome compression here we come!
before and after pics:
putting brass welsh plugs in, got another mod or two to do before she leaves engineering, then im good to go
thats all for now
so my crank was polished and ballanced:
rods and pistons weighed and ballanced, also fitted ARP rod bolts
test fitted mains and big ends to check tollerences, everything measured perfect! then came fitting crank and torquing everything up:
lightened and ballanced intermediate shaft
first we checked the clearance where the rings come together to make sure they are all the same- 0.25mm
then came fitting cofap rings:
compressing rings:
one more to do:
fitting piston into cylinder:
and voila!
all big ends torqued up to spec with ARP special lube- thanks Trippy!!!!!
we also measured the deck height of the piston on each cylinder and they all measure 0.55mm above the surface of the block! awesome compression here we come!
before and after pics:
putting brass welsh plugs in, got another mod or two to do before she leaves engineering, then im good to go
thats all for now
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..../._____________.\.....
../( )====VW====( )\..
.|\_________________/|.
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'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
..../._____________.\.....
../( )====VW====( )\..
.|\_________________/|.
.|_\_______________/_|.
'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
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Re: My ABF Rebuild thread...THE NOOB WAY-UPDATED JULY (no 56
wow, looking good bruce, well done
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Golf II Gti 1.8 16V mp9 viewtopic.php?f=11&t=61202&p=1820503#p1820503
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Re: My ABF Rebuild thread...THE NOOB WAY (no 56k)
Any time budbru-tom wrote:
all big ends torqued up to spec with ARP special lube- thanks Trippy!!!!!
Sinbad wrote:You may be Rockefeller but I'm the Other Fella.
MarshallGTi wrote:dont put honda parts in ur car. thats just not cricket.
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Re: My ABF Rebuild thread...THE NOOB WAY-UPDATED JULY (no 56
Awesome work bud.
She is gonna be wicked when done
She is gonna be wicked when done
2006 E92 335i * Monica
2001 Audi S3 Quattro * Suzie-Q
1999 Jetta 3 20vt 181kw 390nm * Jet-Li
2006 Caddy 1.6 low and slow * Tossa-Caddy
2001 Polo classic 16v ABF Featured * BLUEmotion
1988 Bmw E30 2.9L - Written off
1991 MKII GTI - Sold
1989 MKII CSL - Sold
2001 Audi S3 Quattro * Suzie-Q
1999 Jetta 3 20vt 181kw 390nm * Jet-Li
2006 Caddy 1.6 low and slow * Tossa-Caddy
2001 Polo classic 16v ABF Featured * BLUEmotion
1988 Bmw E30 2.9L - Written off
1991 MKII GTI - Sold
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Saiendra wrote: I cannot argue with you, you bought a BMW out of motorplan...
You clearly have more balls than me.
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Re: My ABF Rebuild thread...THE NOOB WAY-UPDATED JULY (no 56
any issues with installing the ford bolts into the VW rods?
Current Rides
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My Inspiration
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1994 2.0 16v FoxT - Lexy
1998 2.0 8v Mk3 GTI - Liesy
My Inspiration
16vT Engine Pics
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Re: My ABF Rebuild thread...THE NOOB WAY-UPDATED JULY (no 56
Thanks guys,my engineers have done awesome work!
Jerm, the heads need to be machined a tad to fit,but otherwise,no probs
Jerm, the heads need to be machined a tad to fit,but otherwise,no probs
....../.----------------.\......
..../._____________.\.....
../( )====VW====( )\..
.|\_________________/|.
.|_\_______________/_|.
'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
..../._____________.\.....
../( )====VW====( )\..
.|\_________________/|.
.|_\_______________/_|.
'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
- Velofox
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Re: My ABF Rebuild thread...THE NOOB WAY-UPDATED JULY (no 56
bru-tom wrote:Thanks guys,my engineers have done awesome work!
Jerm, the heads need to be machined a tad to fit,but otherwise,no probs
Current Rides
1994 2.0 16v FoxT - Lexy
1998 2.0 8v Mk3 GTI - Liesy
My Inspiration
16vT Engine Pics
1994 2.0 16v FoxT - Lexy
1998 2.0 8v Mk3 GTI - Liesy
My Inspiration
16vT Engine Pics
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Re: My ABF Rebuild thread...THE NOOB WAY-UPDATED JULY (no 56
What was wrong wit your original block that you had to get another block?
If you not going to use the obd2 throttle mind selling it?
She is going to run so sweetly good job
If you not going to use the obd2 throttle mind selling it?
She is going to run so sweetly good job
CURRENT RIDE
2013 VW transporter 2.0TDI
2007 Audi S3
EX
- 2014 Ford Fiesta ST
- 1993 1.8i CITI MP9 98HP 147NM @ KAR
NOW:2.0 ABF 117HP 158NM @Panics on XMS (SOLD)SNIFF
http://www.vwclub.co.za/phpbb3/viewtopi ... 3&t=108203
2013 VW transporter 2.0TDI
2007 Audi S3
EX
- 2014 Ford Fiesta ST
- 1993 1.8i CITI MP9 98HP 147NM @ KAR
NOW:2.0 ABF 117HP 158NM @Panics on XMS (SOLD)SNIFF
http://www.vwclub.co.za/phpbb3/viewtopi ... 3&t=108203