Rebuild kit?

[TrollFromDownBelow]

EDIT: Did not realize how old this thread was. But think the info below is still relevant.

Yes, you can do it yourself, but based on your posts suspect you don't have a lot of mechanical experience. An alternative is to do all but the assembly.

Below is what I did, and is a cost effective way of getting it done right.

- buy the Wilson book, read it multiple times, high-light the good stuff.
- buy the HIGHEST quality parts you can find. There's some excellent suggestions in this string. Weakest link are the heads. Get Len Hoffman heads if you can afford it. I was lucky, and was able to get his 'blue print specials' but as I understand these are no longer available. Next choice would be Adrian, last would be a new set of heads. There practically no rebuildable cores...you might get lucky, but probably best to start with new.
- pull the engine out of the bus.
- I dismantled mine, and bagged and tagged everything, and cleaned upmost of the major gunk. Check with your rebuilder first if they would prefer to do disassembly.
- I took my engine Richard Sedoris located in Youngstown OH. He assembled my long block for what I thought was a very reasonable price. If your in S. IL, this could be a nice little road trip. BTW - he is pretty busy. But definitely worth the wait. If there is machining that needs to be done, he can do some, and will outsource to reputable local shops what he isn't capable of.
- Clean and paint all of your engine tins, and the engine bay while waiting for the engine.
- Re-read Wilson, and install the motor.

I just checked, and it was almost 5 years ago that I bought the parts....IIRC it was about $3500 for the parts (heads were half of that cost) plus what I paid Rich to assemble/build the long block.

Hope this helps.
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1976 Westy (aka Tripod)
2.0 liter FI solid lifters
212k miles

[cabinfourus]

This is a very old thread, but I wanted to add some information I have that may help someone in the future.

Many people who overhaul engines have an idea of what they are going for. The HP, torque, and look of an engine determines the amount of money you are going to spend. If you plan to race your rebuild, it would be smart to find a good machine shop who is willing to work with you and pay close attention to the details of your work. Make sure you can trust the machine shop! Some shops I have dealt with, machined crankshafts that didn't need it. Others have machined crankshafts way too much. I don't like to go past .010 on mains. Just my preference, nothing wrong if you disagree.

Some people are just looking to overhaul their engine to a stock setup, which doesn't always cost a ton of money. If your heads, crankshaft, and camshaft are in good shape, you will save a lot of money. Most crankshafts can be polished and will work fine in a stock engine. The line bore of the case is important, but if you are reusing the old crankshaft, you should be okay. Either way, make sure to check it and that it is within specs.

As far as the specs are concerned, you would be surprised to know that many factory engines are not within the specs they recommend. While working as a line technician in Dodge dealerships, I found many crankshafts that had more clearance than the book called for. If you are looking to get 100k out of your engine's rebuild, make sure to take your time and check everything.

In my years of building engines, I have had some that lasted years and others that failed with less than 10k. The low mileage failures were usually part failures or machine shop mistakes, but I cannot blame a failure on anyone but myself, when I assemble them. You should be checking your specs as you go and will find the mistakes before you fire it up.

I read someone say these engines cost 2000 - 5000 dollars to rebuild, but this is not the normal overhaul. If you use good parts and machine work, you will pay between 1000 - 1500 for a stock rebuild you do yourself. The cost goes up as you add performance parts.

[SGKent]

There is not a "kit" that I am aware of for a type 4 2.0 motor that really meets ones needs. With 30 to 40 years on most of these engines they are no longer "standard" engines. Several of us here can put together kits for you based on what you have however even with no profit or fee in it for us you will still be into it $4000 minimum to do it right. It can be done less costly but it all depends on what you want to accomplish and how long you want your engine to run like a new engine. This discussion occurs once a week around here and there are lots of threads on it. If you want it to run like a new engine you will need new cylinders and pistons, a new cam and lifters, all new bearings, and new heads. The heads will be close to $2000 for the pair.
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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[WhirledTraveller]

[78riviera]

Would the kit from that kustom place Linked to before, be the right kit for my 78 efi 2.0l bus? The 2007cc kit looks.like the right one but I need.somebody to help me be sure. Thanks samba
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Victim of Volkswagen Virus

[curtis4085]

heres my list for rebuild, its still a work in progress. the last few items I borrowed from this thread. i should also mention this is for my 79 2.0 FI bus

Engine Rebuild Parts
Heads – New AMC (Hoffman Automotive Machine, Blueprint Special) * this part is ordered

auxiliary air regulator - 022-906-045A * I have this part NOS
http://www.busdepot.com/catalog.jsp?model=57&category=15

engine gasket kit 029-198-009 German if possible
http://www.busdepot.com/details.jsp?partnumber=029198009

crank seals 029-105-245B and 021-105-247A
http://www.busdepot.com/details.jsp?partnumber=029105245B
http://www.busdepot.com/details.jsp?partnumber=021105247A

piston and cylinders Mahle 029-198-075
http://www.busdepot.com/details.jsp?partnumber=029198075

rod bearings (you need to know what size you have) OEM Kolbenschmidt 039-105-701
http://www.busdepot.com/view.jsp?model=57&category=15&group=10&prodgroup=98

main bearings (you need to know what size you have) OEM Mahle 021-198-491ABR
http://www.busdepot.com/view.jsp?model=57&category=15&group=10&prodgroup=96

Pilot Shaft Bearing 111-105-313A
http://www.busdepot.com/details.jsp?partnumber=111105313A

Oil Strainer - not sure if I need this as I have one?
http://www.busdepot.com/details.jsp?partnumber=021115175

oil cooler - Would like to talk about a new one and also an external oil cooler mounted on underbody
http://www.busdepot.com/details.jsp?partnumber=021117021B (could reuse your old one)

Camshaft Bearing 021-198-541
http://www.busdepot.com/details.jsp?partnumber=021198541

Push Rod Tube 021-109-335c stainless steel if possible
http://www.busdepot.com/details.jsp?partnumber=021109335C

Push rod tube seals - 021-109-345VK Viton

Motor Mount - German
http://www.busdepot.com/details.jsp?partnumber=021199231CMY

Cam Gear, Lifters and shaft - Webcam camshaft 00-732(this is stock) .. I like stock myself , gear CG-002, lifters 00-914
Cam Plug ? not sure what this is
Oil Pump New
Valve springs and keepers
Shims for under cylinders to make up for no head gasket to get correct CR ?
New injectors and seals- best available
Polish and regrind crank
New rods? Or balanced maybe.

Fuel lines, rubber, REPLACE ALL

Engine Compartment Seal, new

Engine mounts, new german
Engine sheetmetal, find all parts that are missing (new screws)
Engine tin bushings, all (hard to find, make what is needed)
Thermostat, new type 1 if missing or expanded
exhaust stud nuts, copper
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Special Thanks to:
Headflow Masters - Vista, CA
www.headflowmasters.com

[gschoep]

I wouldn't have listed it if Webcam didn't offer the service. http://www.webcamshafts.com I know that most rebuilders suggest new cams (but those same people also say that WebCam does good work).

Probably more often than not a Type 4 hydraulic cam is probably damaged beyond grinding. However, it you reusing your cam it may be a good thing to do.

There are probably threads here if we were to search...
http://www.thesamba.com/vw/forum/viewtopic.php?t=366334&highlight=regrind+camshaft
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72 Westy http://www.thesamba.com/vw/forum/viewtopic.php?p=5498034
79 CE2 http://www.thesamba.com/vw/forum/viewtopic.php?p=5476074

[Jalabert]

Sorry, my typo - the kit lists reground cams. (?)
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'73 westy, 1700 type 4 with 34icts

[Desertbusman]

[Jalabert]

Probably a dumb question, but in the kit that the earlier poster linked to it listed reground crank and cam - a reground crank I'm familiar with, but is a reground crank a no-no?
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'73 westy, 1700 type 4 with 34icts

[gschoep]

Seems like this would be a good post to make a list of what would be in a 2.0L engine rebuild kit if there was such an animal.

Here is my contribution:

Heads: rebuilt by reputable builder (example: Adrian at http://vw-offroadmotors.com/) OR
Heads: New (with replaced seats/guides as per Len Hoffman)
Camshaft, Hyd, Reground OR
Camshaft, Hyd, New (Webcam) (drill rivets and reuse old or new gear)
Bearings, camshaft, new
Seal, front and rear main, viton
Hyd Lifters, new (bled with Boston Bob's procedure)
Valve adjustment screws, new
Oil, Pump, type 4 rebuilt or new
(or correct type 1 with modified cover and machined for cam)
Oil cooler, new (arguable)
Piston and cylinder Jug set, with rings
Shims for under cylinders to make up for no head gasket to get correct CR
Crankshaft, balanced and reground
Bearings, crankshaft, new
Gasket set, complete German
Push rod tube seals, Viton
Oil dipstick tube, Viton
Cam plug

Engine rebuild associated parts
Fuel injector seals, new
Fuel lines, rubber, REPLACE ALL
Engine Compartment Seal, new
Engine mounts, new
Engine sheetmetal, find all parts that are missing (new screws)
Engine tin bushings, all (hard to find, make what is needed)
Thermostat, new type 1 if missing or expanded
exhaust stud nuts, copper
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72 Westy http://www.thesamba.com/vw/forum/viewtopic.php?p=5498034
79 CE2 http://www.thesamba.com/vw/forum/viewtopic.php?p=5476074

[RocketRod]

[kyizzle86]

OKay, so while I wait for the book to get here, I need to be finding a solid vw mechanic....Is there a place that has a list of trusted mechanics in the diff states? I live in southern Illinois, and as far as I have found...there aren't many mechanics that seem reliable. Of course, I have mostly been searching the internet, etc so the good ones that aren't online are the one's i have probably looked over....

Anyone have some referrals in the southern Illinois area?

I'm also not opposed to buying a new motor (or rebuilt motor) but I haven't found any in my price range...any input there is good too! Just lookin for direction as I'm new to the engine stuff

thanks for all the input already and for any more!
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~LOLA = '76 transporter; Fuel Injected; A/T; 2000cc engine ~

[Desertbusman]

Best to get that recommended book first. Read and study it then you will be better prepared to ask any remaining questions. And only then will you really know what questions need to be asked. You've got a big task ahead in learning what to do and how to do it.
As far as a kit even if there was one it wouldn't do you much good and that is not the way to go. All of the parts need to be selected individually. You will need to research what's involved with about each and every component. You might start looking for a suitable T-4 specific experienced machine shop. They are very few and far between, but essential to have one to deal with. As far as parts go you will be probably be buying some of them from the shop that you deal with. And other parts from online vendors.
So to recap- Get and study the book to see whats involved. Do that first.
Plan on a lot of coin and taking a long time to do it. And have fun with your project.
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71 Superbug
71 Westy

[BUSBOSS]

[bugger101]

FYI there is actually a engine rebuild kit now available. I don't know about the parts quality though


http://www.kustom1warehouse.net/Type_2_4_Engine_Re...h-1800.htm
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75 west deluxe http://www.thesamba.com/vw/forum/viewtopic.php?p=5270450#5270450

2010 ford focus

[kyizzle86]

Ok, great! thanks for all the help - I'm sure you haven't heard the last of me
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~LOLA = '76 transporter; Fuel Injected; A/T; 2000cc engine ~

[SGKent]

welcome.

You have a 1976 type 4 motor it appears based on your signature. There are no kits. You have to research and build your own. Jake Raby only sells turnkey motors now - about $12,500 according to a recent thread. If you buy parts and do it yourself you will be looking between $1800 and $5000 depending on the condition of your core parts and whether they are reuseable.
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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[Daverham]

Get that book. That's the one.

[RocketRod]

Doesn't Jake Raby sell a hardware kit? Check out his store over at Air Cooled Technology. Most folks decide on what they want their engine to do, detirmine and mic what they have, and order from there. Good luck on your build. And there are many here that have done that with great sucess!
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Why Yes it is a Magic bus!
Common Sense isn't so common.