Type 4 2.0L Engine Rebuild

Wildthings · Samba Member Joined: March 13, 2005 Posts: 50331

Cleanliness and light oil help as well. The fit is supposed to be tight and anything that interferes with it will make the pins hard to get in.

kooper271 · Posted: Mon Feb 27, 2017 6:13 am Post subject: Re: Type 4 2.0L Engine Rebuild

I ground out the piston bores to fit the wrist pins in. However I broke a cylinder, and then my piston ring compressor failed while I was putting a piston in, breaking a ring.

I bought a set of Mahle pistons and cylinders and had no issues. I also got a machined steel tapered 94mm piston ring compressor for ~$35 and it was worth every penny.

My friend who is cleaning out my gas tank and sealing it found a stick inside Laughing

Image may have been reduced in size. Click image to view fullscreen.

And here is the engine currently

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Spike0180 · Posted: Mon Feb 27, 2017 8:00 am Post subject: Re: Type 4 2.0L Engine Rebuild

looking good
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kooper271 · Posted: Mon Feb 27, 2017 8:33 am Post subject: Re: Type 4 2.0L Engine Rebuild

Thanks!

Does anyone know where I can find a clip to attach a CHT sender wire to the head as described in this article?

http://www.germansupply.com/home/customer/home.php?gspage=customer/main/tech/cht/cht_install_2.tpl

Is it necessary to have that clip?

busdaddy · Posted: Mon Feb 27, 2017 8:52 am Post subject: Re: Type 4 2.0L Engine Rebuild

kooper271 · Posted: Mon Feb 27, 2017 9:03 am Post subject: Re: Type 4 2.0L Engine Rebuild

kooper271 · Posted: Wed Mar 01, 2017 8:51 am Post subject: Re: Type 4 2.0L Engine Rebuild

Are the vacuum hoses sold here: http://www.thesamba.com/vw/classifieds/detail.php?id=1988499IN appropriate for a Type 4 Bay?

Most of my vacuum lines were trash, held together with tape and stuff like that.

Randy in Maine · Posted: Wed Mar 01, 2017 9:57 am Post subject: Re: Type 4 2.0L Engine Rebuild

Yes. Keep the fitting that you have though as they will be used in the new silicone hoses.

kooper271 · Posted: Tue Apr 25, 2017 9:18 am Post subject: Re: Type 4 2.0L Engine Rebuild

Moving on, slow and steady.

Shroud is on, valves are adjusted, etc. Need to pull the flywheel to install the felt seal over the needle bearing (if anyone needs one, I have a lot of extras).

I want an oil pressure gauge. A tee screwed directly into the case could snap off, so I bought and put together an oil pressure sensor relocation system from 42 Draft Designs. The stock sensor is there to keep the light off, and I bought the VDO sender for my gauge from Dakota Digital.

The line that came with the kit from 42 Draft Designs was too short, so I went to Summit and got a 24" long black braided brake line.

Wildthings · Samba Member Joined: March 13, 2005 Posts: 50331

Just be aware that the oil pressure switch is going to be very slow to react when the oil is cold. Don't know if you installed screw in galley plugs or not, but if you were to blow a pressed in galley plug on a cold engine the oil light might take a long while to come on.

kooper271 · Posted: Tue Apr 25, 2017 9:35 am Post subject: Re: Type 4 2.0L Engine Rebuild

kooper271 · Posted: Wed Apr 26, 2017 1:02 pm Post subject: Re: Type 4 2.0L Engine Rebuild

Any thoughts on why the 1/2 and 3/4 big tins are so hard to install? They don't want to fit over the shroud or line up with any of the screw holes at all...

timvw7476 · Posted: Wed Apr 26, 2017 2:44 pm Post subject: Re: Type 4 2.0L Engine Rebuild

keep other tin 'loose' to get it all aligned,
you don't get to tighten everything (well, the 1/2 2/3 tins) tight till the
biggest pieces are slipped into place, you are most concerned with the
engagement of the control rod across the top, getting the four screws
into the top of the case, left & right sides, then all the other stuff.
Sometimes a punch and/or nail setter can help pulling it all together.
EDIT: also check around the intake ports, the 1/2 2/3 tins can require
some shaping at times, they like to ride proud there at the intake studs
& cause vacuum leaks later if you don't ensure they aren't fouling the
spacer/gasket surface.

Wildthings · Samba Member Joined: March 13, 2005 Posts: 50331

kooper271 · Posted: Thu Apr 27, 2017 8:47 am Post subject: Re: Type 4 2.0L Engine Rebuild

Thanks for the tips. I think I'm fitting them properly to the fan shroud, but I must be doing something wrong. Nothing is even close to lining up. If I get the two screws into the case, then everything else is off by a half inch or more.

orwell84 · Posted: Thu Apr 27, 2017 9:10 am Post subject: Re: Type 4 2.0L Engine Rebuild

I usually install only the cylinder head upper tin and intake manifolds before installing the engine. This is because intake manifolds often foul on the tin (especially if they are aftermarket) and I can get them sealed properly and am less likely to drop hardware down the intakes. It also makes it easier to get the engine in. I install everything else after. I remove the engine the same way.

Wildthings · Samba Member Joined: March 13, 2005 Posts: 50331

kooper271 · Posted: Fri Apr 28, 2017 9:07 am Post subject: Re: Type 4 2.0L Engine Rebuild

I got these screws in

Not lined up with the fan shroud

Not lined up with the heads

Alternator tin

Another misaligned hole

Wildthings · Samba Member Joined: March 13, 2005 Posts: 50331

Randy in Maine · Posted: Fri Apr 28, 2017 10:49 am Post subject: Re: Type 4 2.0L Engine Rebuild

Suggestion...

Keep the screws loose and just started as you assemble the tinwork. A screwdriver that is just a "pick" is quite handy to get the holes lined up to where they go. Needle nose vise grips can also be your friend.

I like to start at the #1 cylinder and work myself around clockwise from there.


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Type 4 2.0L Engine Rebuild
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