Process of rebuild, replacing heads, new exhaust & misc 1977 FI

[SGKent]

Saturday October 24

Knee felt a little better today so I crawled under bus again.

Wednesday Oct 21

knee a little better today, able to work on bus.

Done:
Install CV joints and torqued to 25 ft lbs twice around on all 4 CV
Trans nose boot and coupler, safety wired - checked to be sure trans shifts
Wire tied last area of oil temp sender wire away from exhaust
Checked trans fluid w/ bus level - was same as when checked w/ trans level
Inspected work to see if missed anything under there
Picked up the last of the tools lying around
Lowered bus off jack stands

To Do:
10. Install oil filler top part
11. Hoses, Throttle cable nut, and AFM install
12. Install AFM harness plug
13. Put engine cover back
14. ECU connect
15. Left Air hose
16. Right Air hose
17. Double relay and resistor pack
18. Add wire ties as needed
19. Head temp wire
20. Oil sender wires
21. Shroud air canister hose
22. Put wire ties on and coil wire
23. Shroud Chassis ground strap
24. Install gravel guard on bumper
25. Install Catalytic back
26. Hook Up Battery and charge
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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

[ivwshane]

Thank you! You reminded me that I need to safety write the coupler!
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77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[SGKent]

[SGKent]

Sunday October 25. It is done and lives. No fuel in the tank so it just ran for a second. I'll get gas in the morning and do a more thorough test. Lord willing, no leaks.

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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

[Clatter]

Your dog just told me he wants to go and frolic on the beach up by Crescent City.

Bet if you get the thing full hot and run it WFO on I-5 for a few hours the trans with be quiet, too.


Time to go get everything 'Bedded in'..
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Bus Motor Build

What’s That Noise?!?

[trailrunnerbus]

[SGKent]

[SGKent]

so far no drips in 20 minutes running and really good oil pressure with just 30 wt break in oil. Praise the Lord. Timing wanders a little trying to set it. The RPM keeps increasing at idle as the engine breaks in for 20 minutes running so that affects it when it get up around 1050 RPM. What is strange is that the RPM was about 200 RPM higher at idle than it was with the old engine. I wasn't expecting that. Not sure if that is a vacuum leak, or the higher compression. Generally idle changes aren't that great with no change of cam.

One thing that does get me, even with all the years experience, is getting the fan belt tension right. I still haven't figured an easy way on a type 4 engine to increase the belt tension just a tiny amount without loosening everything. Most engines one can loosen tension on the lock nut, and using a screwdriver or bar slightly increase the tension. Haven't figured how to do that on a type 4 yet. maybe a block of wood on something as a fulcrum or something like that.
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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

[busdaddy]

How about something like this?:

I'm sure there's commercially made ones as well, but a modified turn buckle isn't hard to whip up at home (pic robbed from the web).
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Rust NEVER sleeps and stock never goes out of style.

Please don't PM technical questions, ask your problem in public so everyone can play along. If you think it's too stupid post it here
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Слава Україні!

[Clatter]

No rebuilt transaxle is as quiet as a factory build.
VW had jigs and tooling that a regular shop will never have.
Best bet to get it quiet is to put a few thousand miles on it.
Dollars to donuts you pull it apart and everything looks fine.

If they don’t whine on accel they whine on coast.
New R/P? It’s guaranteed.

You should hear mine full of aftermarket racing gears;
Sounds like a city bus!


Everything up there on the North coast is beautiful!
There’s a perfect sunrise cup of coffee up there anywhere.
We always just go - open itinerary.
You can park a bus anywhere a car can park.
Some random neighborhood.. Wal Mart parking lot. Anywhere.


Aren’t you supposed to be retired?


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Bus Motor Build

What’s That Noise?!?

[SGKent]

I thought about something like that but the dip stick is in between. What I ended up doing is hold an aluminum block against the case and use a screwdriver to lever it while the engine was idling - tightened just until the belt started to stop vibrating. I am thinking that the hole in the shroud might be used with something that levers it.

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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

[Clatter]

I always just put a big pry bar up in from underneath.

Have to be careful not to go too tight.

Since it’s just an alternator and no fan like a Beetle or water pump like a real car,
You can go easy on belt tension.

As long as your alignment is done well,
And your fan ring is concentric,
Then you can give your alternator bearings a break,
And run the belt relatively loose.

A v-belt grabs by design, even if a bit loose.

Less is best with belt tension IMO.
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Bus Motor Build

What’s That Noise?!?

[SGKent]

[SGKent]

also using the swivel feet adjusted the heads are so quiet that I am not accustomed to hearing all the other noises in the engine. It sounds fine but one hears things that the valve train used to drown out.
_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[cmonSTART]

Turn up your radio.


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'78 Bus 2.0FI
de K1IGS

[busdaddy]

[SGKent]

[airschooled]

That's exactly the boss I use to pry on, with my biggest baddest screwdriver. Helps to loosen the 13mm nut underneath too…

But I also err on the loose sides of non-critical belts; the bearings seem to last longer.

Robbie
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Learn how your vintage VW works. And why it doesn't!
One-on-one tech help for your Volkswagen:
www.airschooled.com

[SGKent]

[orwell84]

Awesome. Change the oil and drive it. Drive it til your tired. Find a camping spot, make a fire, eat Mac and cheese out of the pot and drink lots of beer. Get up the next morning and do it again.

Yeah, I’m not 25 anymore either...