CLKWRKS Upright Conversion

[Clatter]

The engine will be 2100cc, Here is what I have collected so far:
- 2.0 crank & rods
- hyd case with sleves for T1 lifters
- scat C35 cam, udo T1 tool steel lifters
- AA 96mm pistons and stock vw cylinders bored out for the 96mm pistons
- bugpack HD single valve spring kit
- 1.7 rockers with Hyd spacers
- 200mm forged conversion flywheel
- kep 1700lb pp, bugpack 4 puck clutch
- 1800 bus heads 41x34
- electromotive tec 2 efi, with CB throttle bodies


Was this the final spec?

[Piledriver]

The solid rocker spacers from EMW are worth the effort to fit...

[CLKWRK]

Sounds right Clatter, except I used new set of AA 96mm pistons and cylinders, the stock cylinders and AA pistons that I sent to the machine shop were never delivered, I am still waiting on them.
I am using an Electromotive TEC3 6/12 now.
Despite the fact that we were beating on it pretty hard, the oil temp never went over 90deg and the pressure over 4.5bar (65psi)@ 6500rpm.

Here are a couple more specs:
- Hbeam 2.0L rods with arp2000 bolts from cip1
- vintage speed superflow muffler with 411 heater boxes.
- passat 1.8t 22.9lb fuel injectors with 58psi fuel pressure
- type 4 oil cooler

Eventually I will upgrade the rocker spacers

[CLKWRK]

I just got back from street tuning the ghia ... I made it drift on dry pavement quite alot

I forgot how loud the throttle bodies growl on a NA engine
It runs very well with tons of grunt, I have some oil leaks to fix and some other minor things. . I am not happy with sloppy-sounding the steel push rods and will be switching to aluminum.

[Piledriver]

Make sure the rocker adjustment screws are not hitting the valve covers... I'm running Manton pushrods (from the type4store) and it's no noisier than aluminum, unless I get it really hot, and that's the feature.

Properly set up solid spacers help, AFAIK they are from EMW no matter where you buy them.
They are sand to fit, shoot for .003-004 side play.

[CLKWRK]

I don't think its the screws hitting the valve cover because its is very quiet when cold, but gets sloppy when warm. right now I am using hydraulic spacers with wavy washers, when I have time I plan on making a set of spacers that fit perfect with no wavy washers.

[Clatter]

I'll 2nd that steel pushrods are as quiet as aluminum.
Quieter at startup actually, as they start at zero, instead of the .006" or wherever you set the aluminum ones.

Bet you it's your lack of spacers...

Also, after the motor is broken in,
the "loose zero" can be carefully upgraded to "a bit hard to turn with greasy hands"..

Sounds like you're having fun!
Soon as i get the whole rest of my car done I'll be running a similar set-up; can't wait.

[CLKWRK]

Went out for an autumn drive today to stretch the ghia's legs, this video gives a better idea of how loud the exhaust is on the highway:


It is ok loudness for an NA engine, I did a few burnouts
Also those shortened 411 heaterboxes (no aluminum core) pump out tons of heat! After a few minutes on the highway I had to shut them and open up the nostril vents for some cool air.

[CLKWRK]

Yesterday I noticed a drip, crawled under and found the source. It looks like the 1/2 side head isnt sealing properly, the head torque checks out so I will be pulling that head and give the cylinders a lap.

[Clatter]

FWIW, my last set of AA 96s weren't all the same length.

You had your case and heads decked?
Sounds like wrong cylinder length...

AA China parts - they'll drive you to drinking!

[CLKWRK]

the heads were decked, not the case
The cylinders measured out fine when they went in.
Perhaps the case is the culprit, we will find out when it comes apart and I recheck everything.
One thing I did not do is lap the cylinders, which is something I usually do.

[Piledriver]

If the heads are freshly decked, the only thing you should lap them with is toothpaste.
This will show any high/low spots well, cleans up easily, and leaves a minty fresh head.

[Clatter]

Didn't useta be that way,
but now,
Decking a case on a type 4 is now SOP.

[CLKWRK]

I just dropped in a set of aluminum pushrods I had, they look a tiny bit short (thats 1/2 lift)

What do you think? run em or make longer ones

I bet I couldn't go much more than 1/16" longer before the adjuster starts to need more clearance on the rocker

[Clatter]

Why the move to aluminum pushrods?