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Washer dropped in rotary valve

Alban1an

Active Member
Hey guys, had a broken motor mount, so i took the motor out, cleaned out the hull, rebuilt the carb, and was about to put the engine back in l, but decided to remove the oil pump to bench test it since the oil lines were plugged and try to set up the engine with the oil injection again. While trying to put the oil pump back in, I dropped the split washer from the last 5mm Allen screw through the open port in the rotary valve on the PTO side.
I know I should have put a rag, and I was thinking to myself to put a rag in there before I drop something in, and in it went.
That's not the worse part, the worse part is that I tried to take the engine head off and cracked the 1st 11mm bolt loose, and the 2nd one the head broke off.
The engine in question is from a 1997 GTI with a 717 engine single carb.
1. I tried putting in telescoping magnets trying to retrieve it and tilting the engine, did not work
2. I tried shop vacuuming it out, it did not work either, that's why I attempted to take off the head and the olan was to proceed all the way down to the crankshaft.
3. I tried spinning the PTO wheel and it spins without a problem, while hearing the pressure build up, but I don't think I can leave it down there for fear that will create damage down the road, can I?
4. I would like to attempt to take it apart again, but I don't want to snap another bolt, can I take off the spark plugs and spray WD-40 hopefully it will get into the head bolts?
5. Leave it alone and send it out as a core and buy a rebuilt one? If so, anyone know someone reputable, I live in central NJ, can drop it off in the tristate area: NY, NJ, PA and even DE or MD.

Any ideas would help, thanks.
 
I did the same thing. It should not have gone any further the the rotary timing disc. If you never tried to start the ski after the washer fell in there is little to no chance it got sucked in any further. Take off the intake manifold exposing the rotary disc and you should see the washer. I really hope his works for you. Good luck!
P.S--- check the rotary disc for any damage. Even the slightest bend or warp will drastically affect the way it will run. If you see damage replace and re time. It's inexpensive and quite easy to do.
 
Thanks Smikal68. Have been off for a few weeks but there is some progress, rebuilt block, see pictures below.
Also both cylinders hold 150 psi.
 

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