Date:         Tue, 19 Sep 2000 09:47:55 +0200
Reply-To:     Nigel Bennett <NigelB@FOSCHINI.CO.ZA>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Nigel Bennett <NigelB@FOSCHINI.CO.ZA>
Subject:      Decided to Rebuild my 2.1
Content-Type: text/plain; charset="iso-8859-1"

Hi All

Pulled my 2.1 engine on the w/e under the guidance of my brother-in-law who
is a registered BMW mechanic (took 3 hours and I lost plenty knuckle skin).
Engine has about 200 000km (125k miles) on it. Head seals were hard as rock
and the tappet cover (rocker cover) cork gaskets need to be scraped off
because they have turned to wood. Oil pressure sending wire was cracked in
places as well. Stripped the long allen bolt that holds done the A/C
mounting bracket (still have to figure out how to get that out). Lower
engine stud has also been stripped previously. Number 2 cylinder was *just*
starting to burn a bit of oil. There's so much syrup-like goo plastered on
the inside of the heads from the oil-thickner the PO used to check in. The
heads: well, where can I start....Fine cracks in all 4 seats but passed a
pressure test - requires 4 new exhaust valves, 8 guides and I've decided to
spend more on fixing up those cracks - not much corrosion so I guess the
heads were already done by the PO - may need skimming and fly cutting but
the engineers will check.

Some of the water hoses were starting to puff up around the clamps. I will
look at replacing most of the engine hoses as well as the rubber hose
connected to the brake servo *that-should-be-a-hard-plastic-pipe*.

I got a great-looking gasket set from Germany ("Victor Reinz") and the
gaskets do not look like other cheapo makes.

I must say I'm very lucky to have someone to guide me with this rebuild. One
can never put a price to the knowledge gained by experience.

Can't wait to split the bottom end to see the condition of those
bearings.....

Nigel
Cape Town, South Africa
89/90 syncro