924Board.org

jl924t · Joined: 03 Nov 2002 Posts: 214 Location: Surrey, BC Canada

I recently installed a rebuilt engine in my car. The engine is bored out to 87.5mm. I installed flat top pistons, which have a shorter compression height than stock. The car ran great for a couple of weeks, lots of power. The other day I was driving along when it died on me. When I tried to restart it sounded like my timing belt slipped (engine spun faster than normal). I towed it home and checked the belt and all the marks lined up. I put my compression gauge on and found no compression in any of the 4 cylinders. I couldn’t figure out why. I pulled the head and found everything as it should be. I installed a new head gasket and put it back together, still nothing. I thought maybe my head bolts were bottoming out so I put on extra washers and torqued it down, still nothing. I pulled the head again to double check in case I missed something and could not see anything out of place or damaged and it still looked fine (those flat tops sure look pretty). I was turning the crank clockwise and then counter clockwise when the crank bolt backed off. When that occurred the pulley was very loose. I removed the bolt to find that I had sheared the pin that keeps the pulley aligned. Thus the no compression in all 4 cylinders as bottom pulley had slipped. Man am I glad I have a non interference engine. All I have to figure out now is how to remove the ½ pin stuck in the crank with out having to drop the crank. Cheers.
John L.
_________________
1980 924 turbo

Smoothie · Posted: Sat Dec 13, 2003 12:10 am Post subject:

Check past posts. I think Azndrgn had the same thing a while back.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Smoothie · Posted: Sat Dec 13, 2003 12:12 am Post subject:

Here it is -
http://www.924board.org/viewtopic.php?t=6406
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

jl924t · Joined: 03 Nov 2002 Posts: 214 Location: Surrey, BC Canada

Thanks Smoothie.
_________________
1980 924 turbo

Lizard · Posted: Sat Dec 13, 2003 2:02 am Post subject:

JL, I know that Kenodog is rebulding his engine and his was almost about to snap right off, but he caught it in time,

if you are unable to fix it on your current crank drop me a PM, as I have a spare crank, pully, and timing belt cog and key,
_________________
3 928s,

Smoothie · Posted: Sat Dec 13, 2003 4:01 am Post subject:

Hey! - I like that non-interferance modification. What compression readings do you get (when the crank pulley pin's intact)?
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

jl924t · Joined: 03 Nov 2002 Posts: 214 Location: Surrey, BC Canada

Thanks Lizard but I got it out OK. It is just a roll pin so I removed my rad and drilled it out. I'm just putting it back together now. I still had my head off. I should be mobile in a couple of hours. The crank pulley just slipped enough to throw off my valve timing. When I was in my diagnostic stage the camshaft was still turning and the timing marks on the pulleys were lined up so I didn't think that was my problem.

Smoothie when I get it fired up I'll check it. The machinist I bought the block and pistons from said I should be close to stock compression. The pistons are about 3/8" from the deck of the block when they are at TDC. The engine sure pulls strong and I have great compression braking or had. Hopefully I will get running in a couple of hours.

Cheers
_________________
1980 924 turbo

jl924t · Joined: 03 Nov 2002 Posts: 214 Location: Surrey, BC Canada

Success, purrs like a kitten, but a touch rich. I love that sound. No compression numbers yet I want to drive for a while and check when it’s worn in a bit more. Only a couple hundred km on a fresh engine so I think the rings still need to seat themselves. Time for a nap and them go for an early morning cruise.
_________________
1980 924 turbo

Lizard · Posted: Sun Dec 14, 2003 1:29 am Post subject:

good to hear
_________________
3 928s,

Paul · Posted: Sat May 01, 2004 10:39 am Post subject:

So Jl924t did you ever check the compression?

jl924t · Joined: 03 Nov 2002 Posts: 214 Location: Surrey, BC Canada

No, sounds like a project for the morning. Car runs nice and strong I have no issues other than weeping connections.
_________________
1980 924 turbo

Paul · Posted: Sat May 01, 2004 11:52 am Post subject:

Thanks, how's your fuel ecomony and oil comsumption been?

jl924t · Joined: 03 Nov 2002 Posts: 214 Location: Surrey, BC Canada

Oil consumption is 1/2 litre (mobil 15/50)every 2-3 weeks (I put on about 600 km a week). I never really keep specific milage records I fill it up twice a week depending on how far my weekend tours take me. I am on the road early on the weekends and go for a 3 hour drive every saturday and sunday. If I am on the freeway a lot I get around 480-500 km per tankful if I spend a lot of time touring the city streets the range drops to 375 km. Living around Vancouver BC you have lots of destinations, the favorite being the sea to sky highway to Whistler.
_________________
1980 924 turbo

Kenodog · Joined: 25 Jun 2003 Posts: 2669 Location: Vancouver,B.C.

Hey jl924t my ride is going to MCL on May 19 for the final tuning.We should hook up after that and do a cruise.I'll be out of town for work next week but let me know if your interested and we can set something up.
_________________
1979 Euro 931, Olive
1981 931, Sabine
1991 Ford Ranger XLT 4x4, Ricky
1996 Ford E-350 ex-FedEx Van
2014 Mazda CX-5 (Kinderwagon)
2019 KTM 790 Adventure
2024 KLX300
2024 KLX140

jl924t · Joined: 03 Nov 2002 Posts: 214 Location: Surrey, BC Canada

I am up for it when ever you are ready. There is a BBC ( http://gallery.rennlist.com/gallery/albuo57 )on the 8th, auto cross on the 16th and DE on the 31st.
_________________
1980 924 turbo