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Fri Dec 05, 2003 6:02 pm

I just finished my first complete bottom end and top end rebuild in a while. It's a 2.0 liter hydraulic type IV and I installed a 7-pin L-Jet system from my spare inventory. I put the engine in a 1976 Westfalia that I purchased in June with a bad #3 rod bearing causing a nasty knock. Finally got the engine back together last week and installed in the bus this week. After tinkering for a couple of evenings I got it all fired up and idling at 2,000 for the 20 minute break in. Tomorrow I'll take it for a spin and see how it runs on the road. It certainly feels good to stand there listening to that engine purr and smelling that sweet exhaust after putting all that work into it. I'm always a little nervous until I get the engine started and I see it's not gushing oil or knocking like mad. That feeling of accomplishment kinda makes you feel sorry for the poor SOBs that don't enjoy working on VWs. Thanks for reading and take care. :D

Fri Dec 05, 2003 8:18 pm

I am a junkie for the aroma of Fresh Engine Rebuild and have supported my habit by rebuilding engines for the past twenty five years for anyone who wants one. My first rebuild was a '66 Buick Special put together by a bunch of twelve year-olds at summer camp. We had nineteen parts left over. Out of courtesy it ran nonetheless. My best rebuild was a BMW 530i 3 litre straight six with L-Jetronic that ran so gorgeously smooth that I couldn't bear to give it back to the rightful owner, I did a 1,000 mile break-in just to stall for time.
The most recent rebuild was my Bus in August, a slap-happy throw-together mess that broke every rule, but it runs well and had that intoxicating scent of burning carb-cleaner, curing paint, and the famous VW heater box aire d'oile from that blown gallery plug gusher in Texas.
Those who have not had the joy of firing an engine to life after handling all those parts, well. . . . their loss.
Colin

Fri Dec 05, 2003 9:01 pm

Yeah, man I do love starting up a rebuild... like spanking a new born on the ass. :wink:

I also love starting up the upright engines out of the car with my type 2 bellhousing starter rig... really freaks most people out when you crank up a whole engine like that out of the vehicle.
plus if you do have a pesky leak or tuning trouble ( not often for me after all the ones I've done) at least you don't have to fret cause you spent the time to put it in and then find it.

that just makes the FI buses even more satisfying, you have to install it to see it run!

way to go man! 8) give us an update after you road test it :D

Sat Dec 06, 2003 9:31 pm

Do you find that it's better to rebuild your existing engine or to buy a new longblock. I've been wanting to rebuild my engine for a while now. As it sounds like it would be a very rewarding experience plus knowing your engine inside and out. But it seems as though most people suggest that rebuilding is not as cost effective as just buying a longblock. I've been contemplating this for some time now and this thread just reconfirms my thoughts on rebuilding. What do you guys think?

Sun Dec 07, 2003 12:00 am

Building is not as cost effective because you'll have to buy tools and will be inclined to get quality parts for your rebuild. Even for a stock rebuild, that can cost more than a complete engine these days if you don't factor in the refud you'll get from your core.

It depends what you mean by better and cost effective. Will you need two engines to go 120k miles instead of one? If a build problem appears after installation will you be inconvenienced by having to ship off the engine to the rebuilder or would you rather take care of it? Will you be satisifed with the quality of parts they'll use to build an engine including labour and warranty for $1100? Will it be upgraded to compensate for the original design flaws that resulted in premature failure? Will you be trading in nice original cores for a head and case that have been rebuilt several times already? Do you have the time to do it youself or would you rather be driving? Do you have alternate transportation to get parts? Do you have a suitable work area with adequate space, cleanliness and lighting?

Sun Dec 07, 2003 5:36 am

It's hard to justify rebuilding your own engine unless you are willing to pay extra for the learning experience. The cost of special tools and supplies needed for the rebuild will certainly make the cost too high verses purchasing a long block. If you have the time, space, another vehicle, and a desire to learn then go for it. I enjoy working on anything mechanical so I knew several years ago that investing in space and tools would be rewarding to me. My first rebuild was a 1600 dual port that I rebuilt at a friend's house. It lasted 1,000 miles before it spun a bearing, but I still enjoyed it. I now have a 40'x60' shop with all the necessary tools and an inventory of spare parts from two dozen busses. While my friends are spending big money on boats, cars, big screen TVs, and tickets to all the big games, I'm listening to the purr of my new engine and feeling sorry for them.

Sun Dec 07, 2003 6:29 pm

What would you consider to be special tools and supplies for a rebuild?

Sun Dec 07, 2003 8:35 pm

Quality torque wrenches, drifts, mallets, dial caliper, dial indicator, micrometer, engine stand, leak down tester, tap and die set, stud remover, pullers, head cc kit, depth gauge, valve spring retainer, piston compressor, etc.

I would almost call all the chemicals required special also because you'll probably only use them for the engine rebuild and you'll need them also.

Sun Dec 07, 2003 8:49 pm

A minimal list of tools needed are(God knows I will forget something):

*Medium to large floor jack and good jack stands (I use a motorcycle platform jack which is great)
*Ring Compressor
*Flyweel Lock
*Case Splitter
*Clutch Centering Tool
*Small Torque Wrench in inch pounds
*Large Torque Wrench in pounds/kilos
*Dial Indicator-endplay (or substitute a $15 special tool to use feeler gauges)
*Metric Caliper gauge to measure journals and such
*Engine stand or large vice - both if possible
*Kit to measure cylinder head volume: needed to set compression ratio
*Snap ring pliers for wrist pins
*Engine seal kit
*Flywheel and cylinder shims in various thicknesses
*Parts cleaner or large tub with diesel or kerosene
*"How to Rebuild your Volkswagen Air-Cooled Engine" by Tom Wilson and a Bentley Manual
*Plastigauge strips to measure bearing clearances
*Two Kilo postal scale that measures in grams to balance rods and pistons

Lots of soft and hard wire brushes, engine degreaser, Permetex aviation sealant, clean rags, clean work area, sandwich bags for small parts, totally complete set of wrenches, sockets, screwdrivers, feeler gauges, mallets, and hammers. I'm sure there are things I'm forgetting, but that's most of it. You will have to use a good machine shop than can press gears and do your cylinder head work. They are also invaluable to ask questions. If you have a local VW parts store where you can ask a lot of questions that would help also. Most of all you need time and patience and a desire to do it right. I spent about two months of tinkering to build my most recent engine. If you can get your feet wet by doing a top end rebuild only (pistons, cylinders, and heads) without splitting the case then it will give you a glimpse of what a total rebuild entails. Good luck.

Sun Dec 07, 2003 9:00 pm

By the way........the best thing I did when I first became interested in rebuilding an engine was buy a couple of cheap core engines and tear them apart. I bought two type IV engines at a swap for $100, took them home and disassembled them. I then cleaned up all the parts and kept many of them for future use. One case had a thrown rod sticking out the top so it was interesting to see that. I ended up with 2-3 good heads, a good crank, a good case, heat exchangers, rockers, clutch, flywheel, pressure plates, and one nearly complete fuel injection system. However, the best thing I got for my $100 was a better understanding of the engines and the joy of taking them apart. Good luck.

Sun Dec 07, 2003 9:16 pm

ditto on the motorcycle jack. it's a heck of a lot eaier to install the engine when you don't have to keep it balanced on the floor jack.

Mon Dec 08, 2003 9:47 pm

Pay yourself, not somebody else... 'nuff said.

Mon Dec 08, 2003 10:28 pm

I agree with you bottom end. Ive got most of those tools just because I've been slowly accumulating them. The last thing I need is a garage wich I will be getting in a couple of months. Then it will be time to rebuild. Even if it doesnt turn out right I will have gained valuable experience. The next thing to do is figure out where to get good quality rebuild kits and parts for the rebuild. Were would you guys suggest?