Date:         Thu, 17 Oct 2002 14:24:50 -0700
Reply-To:     Ward Smith <wsmith@SAN.RR.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Ward Smith <wsmith@SAN.RR.COM>
Subject:      HELP...any engine builders out there???
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Here's the history..

I just finished a "half" engine rebuild on a 1986 GL. It had an apparent
head gasket leak (blowing smoke), but idleing fine. The Spark Plug from #1
looked the worst so I pulled the right (pass) side head first. Come to find
out the piston was shot. Might have been blowing-by oil and that could have
been the smoke issue. There was a definite antifreeze smell, and the smoke
rose pretty quickly, and there was moisture dripping out of the exhaust, but
I didn't notice the color of the smoke at the time. Anyway, the head gasket
was fine, but the little "sleeve O-rings" were pretty shot, so I replaced
them. I pulled a piston from a donor engine, and replaced it with the burnt
one. Of course both sleeves came off with the head, so I got the fun job of
replacing both pistons inside the sleeves. I would rather perform dental
surgery on myself than do this again!!! Broke one of the rings on the #2
pison, and the rings from my donor engine were not the same size....The
little bell should have gone off here, but it didn't..., so I swapped out
the #2 piston as well.

Long story short, put it all back together filled the crankcase and coolant,
and tried to start her. Nothing. Seemed like a dead battery. (I had a brand
new one) Put a jumper pack on it and the same thing. Nothing. Seemed like
the motor was locked up. I went around back, loosened both belts, and tried
to move the main pulley but it wouldn't budge. On a hunch, I checked the old
vs. new pistons. Yep, different deck height by 4mm. SH*T.

So here's my question, Any chance there is another problem? Please. I
thought the pistons were all fairly interchangeable. The bore was right,
just not the deck height. The engine I am rebuilding is a VW of Canada with
only 50K on it. Remind me to stay away from these.

I think the donor was from an '83. Is the problem 1.9 vs. 2.1? Is that how
they got the extra cc's? I have a brand new set of Cofab pistons but they
are not here in front of me. I will tear the right side apart again tonight
and see if maybe the brand new ones I have are a better fit.

Any help or encouragement would be greatly appretiated, TIA.

Ward