New cam carrier fitted a smoke test showed little difference in the flow past the inlet cam end journal. I put the engine in anyway but only installed it enough to crank it over on the starter with a fully charged battery and STILL only have 1 Bar at 280rpm (measuring blocks) which is not anywhere near enough, two other engines I have recently built showed 3 Bar under non start cranking when I tested them as a reference. The only parts not replaced are the inlet cam (journals checked and to spec), crank (journals checked and to spec), rods (pin bores checked and journal bores checked, block and the chain cover, all of which have been minutely inspected and cleaned obsessively. I built the bottom end up with Plastigauge checking of each of the nine crank journals, all were to as new spec 0.050mm>0.063mm. I don't understand...
The engine is now built with these parts using Red Line assembly lube and the correct genuine selanats on the cam carrier, chain cover gasket and sump.
Everything spotlessly clean, block hot tanked, honed (absolutely no bore wear, still to OE spec) and top skimmed (it had a 0.08mm distortion), all galleries rodded through with cleaning rods.
Nüral pistons (revised design with thicker ring lands), pin bores checked, virtually 0 rock, the pins are pressure fed from the crank.
Genuine oil pump tensioner set
Febi pump chain
Febi full cam chain kit with VVT hub (looks genuine, VAG number ground off!) and oil feed tube
Febi VVT actuator valve (twice)
Genuine injector Teflon seal kits, fitted with the correct tools
Elring gaskets right through inc metal head gasket and head bolts
All other fasteners new genuine such as crank and rods as required (BIG pile)
Genuine diamond crank washers, Oil seal sleeve and “O” ring
Genuine between block and head oil strainer
Genuine revised design oil filter
15w/40 mineral oil to VAG spec
Professionally rebuilt turbo (oil pressure tested with this out of circuit, made +0.1 Bar increase)
Genuine water pump
Plugs and coil packs
VDO manifold flap motor
Febi Fuel pump tappet
Genuine piston cooling jets, revised design
Febi oil cooler
Glyco bearings (Plastigauge checked)
KS main bearings (Plastigauge checked)
Genuine thrust washers, feeler gauge checked at 0.15mm thrust
Genuine revised cam carrier
FAI exhaust cam
INA roller fingers
Genuine
FULL cylinder head with equaliser elements
Genuine oil pump, “O” ring and revised design pickup
Genuine turbo oil feed pipe
Febi crank flywheel oil seal pressed on with the genuine tool
Genuine oil gallery plug
Really this is getting silly!