I'm on about literally grinding down the block/starter lol

That would he pretty retarded Eric

yeah i know, but what if it worked? people would eat hats and everything. lol

atm I'm trying to get about, with that dodgy ass starter. sometimes it takes ages for me to get it started! i know i need to take the slim one apart and investigate, but i need one in the mean time! cant just bumpstart it every day haha!

So you want to start grinding away some of your block to solve this problem? Try it by all means but remember what happened when you tried to drill the exhaust stud out and didn't know how far to go? Imagine that but with a engine block instead of a head. Seriously its a disaster waiting to happen. Having offered up a fat starter to the AVY block I'd say it would need a fair amount removing from both the starter housing and block to allow it to sit how it should

Look at Mikey's FAQ, its just a case of swapping internals, you could do it on your kitchen side in the warm with no chance at all of it killing your engine

okay dudeee. i have silly moments you know me. lol

So you want to start grinding away some of your block to solve this problem? Try it by all means but remember what happened when you tried to drill the exhaust stud out and didn't know how far to go? Imagine that but with a engine block instead of a head. Seriously its a disaster waiting to happen. Having offered up a fat starter to the AVY block I'd say it would need a fair amount removing from both the starter housing and block to allow it to sit how it should

Look at Mikey's FAQ, its just a case of swapping internals, you could do it on your kitchen side in the warm with no chance at all of it killing your engine

Good advice,

Dont bodge the block. If you can swap the internals over just do that.

I've got a avy starter are those the same

Edited 12 November, 201213 yr by georgen

Has the wrong pinion throw for the earlier flywheel he's using mate

I already have a mk4 starter lying around somewhere but thanks.

So i need to have a look and see which brand my starter is. With a bit of luck its just a broken/worn brush or magnet like mikey had.

What is the headbolt issue with these? About the bolts being too skinny or summin

Yeah the avy head bolts are thinner than the afh head bolts and slightly shorter.

So you have lots of clearance on the afh head when you fit it to the block using the avy bolts.

You can drill and tap the avy block to suit the afh bolts, you can do it yourself just make sure you tap nice and square and dont snap a tap. Ensure no swarf goes down any of the oil/water ways or in the bores.

Has anyone actually drilled and tapped the avy block before though? Wanna know theres enough meat on the block.

I was worried that the head could move due to the bolts being too small

Intrested in this also .. the sleves sound like a good option .. would this effect torqing the head up ?

People have had the avy drilled and tapped before. Why wouldn't there be enough meat? It's the same block as the afh after all. And the avy head bolts shouldn't be used with this setup as they are the wrong length, iirc its 1 litre 6n2 head bolts you need to use if not modding the block to take the afh bolts

So if i drill and tap afh headbolts fit??

Compression test results:

Cyl 1. 245 PSI (had oil on the plug)

cyl 2. 220 PSI

cyl 3. 220 PSI

cyl 4. 225 PSI

that makes me think i must have some stupidly high compression ratio?!?! And I'm guessin thats why my starter wont turn it properly.

Is there any way of me beefing up a slim starter?

Those pressures are spot on for the AVY & AFH 10~15Bar just your #1 is @ 16.8 Bar

Really? Blimey! I thought that was relli high.

Could cyl 1 be caused by a leaky HG leaking oil into the bore sealing it

The early starter would probably get hit by the crankshaft if you removed the sidewall to allow for it. And you'd spill about 78 litres of oil on the road per mile.

The smoke, well it aint oil or coolant. Did you forget to put the jets in or something..?!

The AFH head is too tall for the skinny bolts. There should be locating pins on the block to ensure the head is in the right place, you need to use them because the valves are close to the top of the bores. If you haven't caught your valves then it can't be far out.

The head bolt issue is that being longer, the spring rate is lower with the same torque. Longer bolts are more stretchy, basically. So you'd wanna torque them to 40nm primary instead of 30nm to make up for this.

I have always suggested putting the internals into the older 1.4 block which has all the correct threads engineered into it, and i always will recommend that. People persist in using a GTi block and persist in having problems..

Those pressures are spot on for the AVY & AFH 10~15Bar just your #1 is @ 16.8 Bar

Thats good news then. Rings should be ok.

The HG may have failed on cyl1 then, and the oil sealing it when doing a comp test.

The early starter would probably get hit by the crankshaft if you removed the sidewall to allow for it. And you'd spill about 78 litres of oil on the road per mile.

The smoke, well it aint oil or coolant. Did you forget to put the jets in or something..?!

The AFH head is too tall for the skinny bolts. There should be locating pins on the block to ensure the head is in the right place, you need to use them because the valves are close to the top of the bores. If you haven't caught your valves then it can't be far out.

The head bolt issue is that being longer, the spring rate is lower with the same torque. Longer bolts are more stretchy, basically. So you'd wanna torque them to 40nm primary instead of 30nm to make up for this.

I have always suggested putting the internals into the older 1.4 block which has all the correct threads engineered into it, and i always will recommend that. People persist in using a GTi block and persist in having problems..

What did you watch the video on mikey? Looks to me that theres blue/black smoke in there. Mostly white.

Ok the starter issue...

I only have a 360 amp starter.

Used the train jump starter on it set to give me an extra 70 amps, fired straight up.

Guessing i need a better battery. Opinions?

I'd strongly recommend upgrading your cables mate, the standard stuff is really gay.

Think my batt is One of the highest CCA ones of its size available, but was £70 odd.

Sleaves are a good idea yes, however the avy headbolts holding down the afh head seem like bungie cords, i didnt like tightening them up i was scared i would snap them as they dont go into the block that much.

Also if you look at the torque settings for the headbolts the afh are almost double, this may be because they are bigger, but vw obviouly thought it needed them.

I believe there is enough meat on the holes to drill them out, the block is very similar to the afh block, they probably started with the afh block when they designed the avy in cad.

If your going for more power in the future its well worth doing it next time you have the head off.

At least your bottom end and valves seem alright from the results of compression test.

Whats your next step going to be? Head off and have a ganders at the gasket?

Also i have thge same battery as you, halford special? Mine seems fine but yours might just be fucked.

You can use the starter cable and alternator loom from a mk4/5 if you want a quick upgrade, it can only help.

I have a bosch silver battery. Turns mine over for ages. £50-odd delivered from ECP with club discount

The early starter would probably get hit by the crankshaft if you removed the sidewall to allow for it. And you'd spill about 78 litres of oil on the road per mile.

The smoke, well it aint oil or coolant. Did you forget to put the jets in or something..?!

The AFH head is too tall for the skinny bolts. There should be locating pins on the block to ensure the head is in the right place, you need to use them because the valves are close to the top of the bores. If you haven't caught your valves then it can't be far out.

The head bolt issue is that being longer, the spring rate is lower with the same torque. Longer bolts are more stretchy, basically. So you'd wanna torque them to 40nm primary instead of 30nm to make up for this.

I have always suggested putting the internals into the older 1.4 block which has all the correct threads engineered into it, and i always will recommend that. People persist in using a GTi block and persist in having problems..

This is the route i want to go down as the head will match and wont have issues with drilling out avy block ..

Only thing thats making me doubt this route is you've said somewhere that the crank pully has to be one off a 1.4 16v golf as the afh/avy one does not fit the casing correctly ?