Project Hole-In-One

 

Part 12 - Minor mechanical things

   First of all, a quick apology for this being a text-only installment.  We forgot to bring the camera with us over to work on the car, and with sunlight fleeting this time of year, we decided to get the work done and rely on my writing ability to convey Part 12 of Project Hole-In-One.

   Updates are aplenty for Project Hole-In-One.  First of all in order to simplify my life (not to mention the parking situation at my parents' house) I decided to part with the rally car.  Eric Parham, a fellow club member and racer of some note is the new owner.  I hated to see it go, but I've spread myself a bit too thin lately.  I still have a pile of parts, including wheels and tires as well as a nice Sparco steering wheel and adapter.  If I don't sell these parts the might find their way onto another project car.

   We've also put the Fastback out on the market, as I'd rather it go to a new (and hopefully warm and dry) home rather than risk it rotting away on the lawn over at the 'rents' place.  Again, not something I want to do, but without a garage and with no interest in renting one, I want to do what's best for what is a really solid and unique car.

   With the (relatively) unrelated news out of the way, and after a few weekends filled with family and social obligations, we finally decided Sunday afternoon (10/20) to tackle the cam and lifters on Project Hole-In-One.  As many of you probably know, noisy lifters are a common problem on water-cooled VWs with hydraulic lifter heads.  The causes of the noisy lifters are many.  Worn valve train components, varnish and gunk in the lifters, or low oil pressure can all lead to that embarrassing ticking noise.  After oil changes and additives failed I bit the bullet and ordered up some new lifters from IMPEX.   With the motor running well otherwise, I figured my problem was simply worn out lifters and not an indicator of something more serious (read expensive).

   Now, as anyone who has ever brought their car to the dealership can tell you, when you're doing a job like replacing noisy lifters, there are several little side jobs you can do since you have the car apart anyway.  In my case I decided to take advantage of having to remove the camshaft anyway to do a little upgrade.

 Rather than try to make you believe that I spent all this time researching the right cam for my application, the truth is I happened upon a eBay auction for an OEM VW "Sport" cam, new in box.  Seeing the specs (listed right).  The price was within my budget and the specs sounded close enough for my tastes. I was looking for a cam that would wake up my otherwise mostly stock GX code motor without killing the idle or engine vacuum.

   Sunday afternoon around 4 o'clock we rolled into my parents' yard and started tearing into it.  Having already taken the motor apart this far before to replace the timing belt and tensioner (see Part 9) the parts I needed to take off to get at the timing belt SHOULD have been a piece of cake to remove.

  And they were, except for on Allen bolt on the crank pulley which rounded out on me.  To be honest, I started rushing things and wasn't careful with the Allen wrench.  As a wise man (actually a former manager) once told me, "you never have time to do something right, but you can always find time to do it over."

Old Cam   New Cam
.400 lift (inches) .440
Approx 245 advertised duration (degrees) 268
110 overlap (degrees) 110

Cam specs courtesy Techtonics

   With the gentle application of the ball end of a ball-peen hammer, I eventually got the last crank pulley bolt out.  It was downhill from there as I got the rest of the parts off, removed the old cam and lifters, swapped in the new parts, and buttoned everything up.  Not counting the extra time I took stripping out the fastener, the whole cam swap took about two hours.  A quick break-in of the new cam and lifters followed by an oil change, and Project Hole-In-One was back on the road.

   Now the main thrust of this exercise was to get rid of the annoying lifter tick; anything above and beyond that would be a bonus.  The results are much more than I expected.  The engine now runs quiet (though I think I'm hearing a slight exhaust leak coming from somewhere) and the cam really woke up things.  Now the car pulls real good, especially considering is humble base.  The dead spot in the middle of the rev range is now gone, and the car will pull as far as I want it to go without laying over at any point.  Since I didn't replace the valve springs, I've kept things under 5,000 RPM for the most part.

   Conclusions?  Well, my first conclusion is that the only real solution to noisy lifters is to replace parts.  Figure out if its an oil pressure problem or a valve train problem and fix it.  All the additives in the world are nothing more than a stop-gap measure, and all this talk about certain oil filters being better because of a "special valve" in them is an urban legend.   Conclusion #2 is that nothing changes an engine's personality like a camshaft, even a lowly 85 HP GX code motor, with its small valves and low compression.

Random Notes

  • Now that Project Hole-In-One is my primary mode of transportation, I need to come up with another car to drive while its in the shop getting the rust repaired and the bodywork completed.  I hope to have this taken care of in the next week or so.  Could be a Winter Crasher, could be another project car.  You'll just have to wait to find out

  • While the camshaft did increase the performance of the engine, it also exposed the next weakest link in the chain; the transaxle.  The transaxle is in excellent condition, but its wide-ratio gearing and high final drive ratio, while great for economy, are not conducive to spirited driving.  While I don't see anything being done about this short term, when the current clutch finally needs replacement, look for a close-ratio gearbox (possibly with a limited slip differential) and a light weight flywheel to replace the stock components.

  • Continuing with the lightening kick I'm on, I've taken a liking to Rota Slipstream wheels.  While the color hasn't been finalized yet, look for a set of Slipstreams on Project Hole-In-One as soon as it returns from the body shop.

Hopefully Part 13 will find Project Hole-In-One in the shop for some rust repair, and maybe even some body work.  Stay tuned...

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