2.0 Conversion running issues!

[ashleytofield]

Hi there, yesterday I fitted my new engine (2.0 bottom end and 8v mk2 head) all is up and running I've just got a couple of issues

1) the power steering fluid is bubbling all over the place, and even gushing out of the reservoir cap. The power steering pump is making a strange noise and vibrating. I refilled it with the correct fluid, and how the haynes says you should.

2) when the engine is idling it is hunting. It will idle fine for a few seconds, the revs will drop for Literaly a second, then it will be fine for a few second and so on. All the airflow etc are from my old engine and I never had this problem before.  

Any advice or ideas For me to try would be much appreciated

Thanks!

[mk2bal]

Sounds like your pas has an air lock. Not sure how to remove it, but try going full lock 1 way to full lock the other, keep doing it, it may overspill at first but hopefully will gulp a load and sort itself. I'd say your idling issue is either a sensor or something similar disconnected, or a vacuum leak. If it wasn't there before you can prob narrow it down to something you've done..

[ashleytofield]

Hmm I did try going from lock to lock, and starting the engine a couple of times to try and draw the fluid through. I'll give it another shot tomorow. The only other thing I've changed Is putting a cone filter on, could this be affecting the idle? Thanks for your reply

[Wayne]

Reference the pas, remove the cap and turn lock to lock 8 to 10 times and that should get the air out.

[danny_p]

pas fluid bubbeling means you have a leack.

it'll be on the low pressure (gravity feed to the pump) usally right by the pump,      pipe gets a pin hole in it and pump draws in air though it.

[ashleytofield]

Right I've fixed the power steering, valve in the pump was stuck open so the fluid was circulating constantly. I've also fixed the idling issue (hopefully), I refitted the standard airbox and vacuum hoses and it's idling alot smoother now.

The only problem I've got now is the coolant flange on the front of the head is leaking. I had this problem before and used some gasket paste which seemed to fix it but I tried this and it didn't work. I'm going to give it another crack tomorow but I was just wondering if anyone else has had this problem and if there is another way to solve it?

Thanks

[russ-vdub]

Clean all the faces properly and get an new o-ring seal, its a simple as that really. You cant reuse the same o-ring, it'lll never seal properly. Also make you get a VW one, Gsf ones are generally slightly smaller.

[Diamond Hell]

Replace the housing with one from VAG.

They're not dear and you'll have peace of mind.

The housing will have distorted over time which is why it's stopped sealing.

[ashleytofield]

Thanks for the help guys, leak is all sorted now but the power steering is giving me trouble again! When I turn the wheel when I'm stationary the revs drop, it's not like the rev drop you might expect normally, if you turn it really quick the car almost stalls! It's had a new pump so I know it's not that. Only thing I can think if is that the gland on the feed pump is letting air into the system (could be damaged from the amount of times I've had it on and off!) which is making the pump struggle.

Any advice would be great because I've got the dreaded MOT tomorrow!