TheSamba.com :: View topic - Everyone else has a project thread

Sat Jun 21, 2008 5:32 pm

Well, everyone else seems to have a project thread, so here goes mine.
I am getting read to drop the engine on the 73 Fastback for a rebuild. This engine needs to be finished so the car can be driven to the 08 Invasion.
I haven't decided yet if it will be a 1600 or a 1776. I have a set of Cima 90.5's and I have a set of Mahle 85.5's that should be here monday by fed-ex. I think it will depend on if I need to send the case to Rimco for any other machining.
This engine is definitely a virgin. Never been out of the car. There are things that the factory did during production that the mechanic does not need to do.
Like route the backup light wires through the loop on the back of the intake air distributor. The intake air boot is original, but has a small split on the bottom.
Right now I am waiting for it to quit raining so I can finish pulling it. I did find something that would explain some of the funky running. When I went to disconnect FI harness, the wire that controls the fuel pump was not tight. It fell apart when I disturbed it.
I will save Everett some bandwidth and just post pictures on my web site.

http://classicvw.org/gallery2/v/yellow+fastback/engine+build/

Sat Jun 21, 2008 5:58 pm

Wow. I ALWAYS route my backup lights that way. :lol: You're right, though... there are ways you can tell. For one thing, bolts/ nuts are not too tight/ too loose/ rounded off or otherwise damaged. For another thing, nobody "improved" upon anything. Third, all those "unnecessary" parts are there. Fourth, the engine probably isn't "sealed" to the transmission with six tubes of silicone.

Yeah, it's amazing what you can see out there. All OE is a delight to be savoured, indeed.

Sat Jun 21, 2008 8:08 pm

Russ Wolfe wrote: Well, everyone else seems to have a project thread, so here goes mine.
I am getting read to drop the engine on the 73 Fastback for a rebuild. This engine needs to be finished so the car can be driven to the 08 Invasion.
I haven't decided yet if it will be a 1600 or a 1776. I have a set of Cima 90.5's and I have a set of Mahle 85.5's that should be here monday by fed-ex.
Right now I am waiting for it to quit raining so I can finish pulling it. I did find something that would explain some of the funky running. When I went to disconnect FI harness, the wire that controls the fuel pump was not tight. It fell apart when I disturbed it.
I will save Everett some bandwidth and just post pictures on my web site.

http://classicvw.org/gallery2/v/yellow+fastback/engine+build/

I think I'd leave it as a 1600 myself. After driving the Notch with the FI working good, it really moves the car along.

Sue and I were trying to help you make some room in your shop while we were there. In fact I know Sue would have been more than happy to help you organize and stack crates, as she thought you had a pretty good pile of parts scattered out there, and wondered how you could find anything. :wink:

Sun Jun 22, 2008 6:47 am

You'll probably be done and driving before me.

DAMN !

Sun Jun 22, 2008 6:51 am

COFBack wrote: You'll probably be done and driving before me.

DAMN !

are you kidding..... it'd be different if Russ actually slept...

Sun Jun 22, 2008 6:59 am

There's not anything wrong with that 1600, if its dialed in you'll have plenty of get up and go. I run a 1641 with 2 re-jetted webber's and it runs as good or if not better than some bigger motors.

Sun Jun 22, 2008 7:47 am

Yeah, my 65 Notch (a 1600 with dual Solex carbs) ran great all the way to Hershey and back. And we weren't exactly doing the speed limit either. :wink: Of course now with higher gas prices, a little 1600 might be the way to go too. :roll:

Sun Jun 22, 2008 7:52 am

blankmange wrote: COFBack wrote: You'll probably be done and driving before me.

DAMN !

are you kidding..... it'd be different if Russ actually slept...

Us old people take a lot of short naps.

Sun Jun 22, 2008 11:30 am

More progress today. Added some more photos.

http://classicvw.org/gallery2/v/yellow+fastback/engine+build/

Sun Jun 22, 2008 2:33 pm

Congratulations on getting the engine out, especially solo. Nice to see how it all should be disassembled: I was doing mine all wrong. So, thank you for the pictures.

I bet the engine was running hot with all the junk on/around it, then compounded by the lack of thermostat.

Sun Jun 22, 2008 5:36 pm

Not lack of thermostat, just a bad one. The shutter did what they were supposed to. they went wide open.

And I found something else. I was finding pieces of aluminum in the heads and cylinders as I was tearing it down. I found the source.

The engine is apart, except for the crank. Looks pretty good. Case is usable without an align bore.

Sun Jun 22, 2008 5:40 pm

nice work russ! the fan was the source then?

that FI harness looks like it's in great shape. If you weren't one of the T3 gods around here I'd have "tips" but there seems to be no point in that! :lol:

Sun Jun 22, 2008 5:43 pm

Excuse me for misstating.

So, what caused the pulley to shear/get damaged?

How do you know it does not need to be align bored? I thought the flywheel play dictated that it needed to be bored?

Sun Jun 22, 2008 5:44 pm

You can usually see excessive center bearing wear when it needs a line bore; he's got the crank off so he can see. Also, you can lay a straight edge across the bearing saddles in each side of the case and measure for alignment.

Sun Jun 22, 2008 5:44 pm

architect_7 wrote: Excuse me for misstating.

So, what caused the pulley to shear/get damaged?

How do you know it does not need to be align bored? I thought the flywheel play dictated that it needed to be bored?

maybe he checked the flywheel play already :wink:

Sun Jun 22, 2008 5:55 pm

JSMskater wrote: architect_7 wrote: Excuse me for misstating.

So, what caused the pulley to shear/get damaged?

How do you know it does not need to be align bored? I thought the flywheel play dictated that it needed to be bored?

maybe he checked the flywheel play already :wink:

Which stated that it did need to be aligned. Check the picture's captions, it is there.

The interest is I have an auto '69 engine (which meant I could not go to the meet (not with all that weight)) and a '71 case.

Sun Jun 22, 2008 7:24 pm

architect_7 wrote: Excuse me for misstating.

So, what caused the pulley to shear/get damaged?

How do you know it does not need to be align bored? I thought the flywheel play dictated that it needed to be bored?

The pulley is worn because this has been a gravel road car all its life. There is sand and gravel all through the engine cooling system. This sand and gravel has been wearing on the soft aluminum pulley and wore it through.

As for the align bore I checked the end play in the engine before I pulled the flywheel. The measurements I got, told me how much wear to expect. In either the main bearings or the case. I have that wear in the main bearing. Not in the case. The main bearings were extremely worn. If it was a customers engine, I would align bore the case, but this is my own engine, and I know what to expect. I think I can expect another 75,000 miles out of this engine.

Sun Jun 22, 2008 8:09 pm

Russ Wolfe wrote: architect_7 wrote: Excuse me for misstating.

So, what caused the pulley to shear/get damaged?

How do you know it does not need to be align bored? I thought the flywheel play dictated that it needed to be bored?

The pulley is worn because this has been a gravel road car all its life. There is sand and gravel all through the engine cooling system. This sand and gravel has been wearing on the soft aluminum pulley and wore it through.

As for the align bore I checked the end play in the engine before I pulled the flywheel. The measurements I got, told me how much wear to expect. In either the main bearings or the case. I have that wear in the main bearing. Not in the case. The main bearings were extremely worn. If it was a customers engine, I would align bore the case, but this is my own engine, and I know what to expect. I think I can expect another 75,000 miles out of this engine.

Thank you for your kindness in helping understand engines.

I saw the gobs of gravel/dirt, and commented on it. That amazes me that it could wear the pulley that much though.

If the main bearing took the damage, how come the case would have to be align bored? The bearings took the wear, not the case, right? Why 75,000? I though a rebuild lasts 100,000 miles?

Sun Jun 22, 2008 9:20 pm

There is a slight amount of wear in the case. Not enough to be concerned about for an engine of my own. If it was a customers engine, I would want it to be perfect.
I may still go ahead and bore the case. It depends on what bearings I have in stock. I still need to go through my stock of bearings, and see what I have. I know I am getting short on STD/STD main bearings. I know I have quite a few sets that are STD crank and first oversize case with first oversize thrust.

Sun Jun 22, 2008 10:00 pm

Looking good!, buddy!

I think the 1776 will be better.

Keep us posted, russ.