Date:         Sun, 20 Feb 2000 20:54:15 -0700
Reply-To:     Gary <glee@ULTRALINK.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Gary <glee@ULTRALINK.COM>
Subject:      rebuilding a 2.1 engine.  tips, suggestions wanted
Content-Type: text/plain; charset="Windows-1252"

Hi everyone,
I'm rebuilding my 2.1 vanagon engine, about 150,000 kms on it.  I have
rebuilt many other types of engines, but this is my first VW flat four.  I
have the engine apart and have inspected everything, tolerances are
acceptable.  Cost is a consideration.
I plan on doing the following:
1.  Getting heads rebuilt with guides, seats, new exhaust valves.  Rebult is
about 1/2 price of new heads.
2.  Use old lifters and push rod tubes.
3.  Re ring only, not new sleeves and pistons.
4.  New cam bearings, rod bearings.  Use old main bearings.
5.  Complete gasket set.
6.  Should I resize big end of rod bearings?

Am I doing anything wrong?
Is there any other things I should do?
Anything peculiar about this engine I should be aware of?
The sealing surface between the head and the cylinder sleeve looks good, no
damage, but I was advised that I would have leakage problems.  Is this a
problem area?

Any tips or suggestions would be very much appreciated.

Thanks
Gary