Rotary Valve Mayhem

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orionz

New Member
Hey y'all...I did the old air box bolt down the carb trick to my otherwise almost pristine '97 GTI two weeks ago. My fault...I own it. Pictures follow. By researching the forum I know: 1) new RV required...duh 2) new RV shaft assy (with brass gear) required. Questions for you guys: a) if I smooth out the damage to the affected port on the case and the RV cover do you think that will do it? Or will some kind of additional repair/machining be required? Both appear in good shape otherwise. Virtually no grooves in the faces and only two small divots (pic 3) adjacent to the affected port. b) Must I split the cases to clean out the contaminated oil and any brass debris...or is there a way to just flush the stuff that's in there (along with any residual brass debris) out? I know the conventional wisdom is just get a short block and drop it in...BUT this motor has been amazingly reliable over 26 years and if I hadn't made a bad mistake it still would be...I'm trying to save it. My experience with SBT replacement blocks has been less than confidence inspiring. Your thoughts and advice please. TYIA. PS...I have the offending bolt...it's cut half way through...but it's NOT in the engine.
 

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Cover and cases look fine just smooth out any burrs.
You need to split the cases to replace the rotary gear and shaft.
 
Same exact problem happened to my 93. Do we really need to split the case? I’ve seen some other YouTubers remove the Circlip and DIY tool the rest.
 
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