Date:         Tue, 20 Apr 2004 21:52:58 -0700
Reply-To:     Mark Seifert <theburnvictims@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Mark Seifert <theburnvictims@HOTMAIL.COM>
Subject:      Re: Tools for engine overhaul on 85 waterboxer
Content-Type: text/plain; format=flowed

When I rebuilt my 2.1 waterboxer, I never needed any special tools. I used a
slide hammer to pull the wrist pins out. I pulled the clips out of the side
facing the hole, and left the other clips in. Then i put the threaded part
of the slide hammer through with a nut on the end, and the pins came out
with a little effort. I didnt have to use the special reamer tool or
anything like that.  Make sure you have some small circlip pliers to fit
through that hole. This was the most difficult part for me. I found that the
pistons were easier to work with if the sleeves were removed. That's why
putting them back in was more difficult. And you have to be very careful not
to let the rings pop out. I had to put all my cylinders in twice because of
this mistake. You have to put the rear cylinders in first (closest to
flywheel), as the front cylinder will block the hole. So if the rings pop
out of a rear cylinder, you have to take both off and start over. You're
supposed to use a special tool to hold the rods in place to get the pins
back in. The way I got around that was to put the motor on a bench, with the
flywheel down. That way I could just turn the motor until the rod lined up
with the hole.  If you have rebuilt air cooled motors, then I'm sure you
know about pressing the gears off the crankshaft and heating them to go back
on. That was fun. Other than that, I cant think of anything else besides a
dial indicator to check end play. Everyone has told me not to use the
click-type torque wrench on the heads. Not sure exactly why, but they preach
it, so I listened. I bought a cheapo pointer-syle for $11. Those dont seem
very accurate, but I dont think it has to be exactly 37 lbs anyway. Cant
think of anything else right now. This is basically an air-cooled vw motor
with a water jacket, so the only BIG difference is the pistons/sleeves. I
would recommend NOT buying special tools. If someone will let you borrow
them, it would probably be easier but...anyway, Hope this helps.
-Mark


>From: Don <Williams@BIOL.WWU.EDU>
>Reply-To: Don <Williams@BIOL.WWU.EDU>
>To: vanagon@GERRY.VANAGON.COM
>Subject: Tools for engine overhaul on 85 waterboxer
>Date: Tue, 20 Apr 2004 11:05:45 -0700
>
>I need to overhaul my new (to me) 85 Westfalia with the standard
>waterboxer engine.  I need the specialized tools that are required to
>remove/replace pistons and sleeves and any other specialized tools
>(removing circlips and piston pins, it looks impossible through that
>little hole.  .  Are there others besides the piston/sleeves issue??
>How can I make/borrow/buy them.  I have overhauled air-cooled engines
>many times---this is a whole new trip for me.  I haven't been to the
>dealer yet, but this could cost me a small fortune just for the tools??
>Thanks for any help you can give me.
>Don

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