Date: Sun, 9 Nov 2008 23:00:50 -0500
Reply-To: Dennis Haynes <d23haynes57@HOTMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Dennis Haynes <d23haynes57@HOTMAIL.COM>
Subject: Re: 2.2 Rebuild Questions
In-Reply-To: <49179FB1.9050706@shaw.ca>
Content-Type: text/plain; charset="us-ascii"
The green o-rings at the top of the cylinders do very little to keep the
combustion gasses in and the coolant out. Most likely your have loose heads
as the result of improper torque at installation, overheating, or the studs
are just no longer doing their job. As the gasses keep leaking, the top of
the cylinder can erode which will just make things worse. When the engine
cools, instead of gasses going out, coolant will get in. Just a little bit
of coolant is all that is needed to burn holes in the tops of pistons and
anything that gets past the pistons will make short work of the bearings.
Heated coolant and air make a great corrosive.
Except for blueprinting and balancing, stock will give the best longevity.
There is little proof that coatings and magic stuff will really make the
engine last longer. When the water pump belt fails or a hose blows, it
doesn't matter anyway.
Avoid the temptation for a larger pump. This will only increase consumption,
foul catalytic converters, and in winter, the oil pressure relief may not be
able to handle the increased flow so you will get to blow oil filters and
maybe even break a pump shaft. How do I know?
It is really unlikely that the crank will need machining.
Of all the engine parts, the case and the studs really cause the most grief
after an overhaul. If the case is not straight, then the heads wont seal,
the bearings won't line up etc.
When you open the case, look carefully at the center webs, If there is any
sign of wear where the case halves meet, (the machining marks worn shiny),
then the case is also worn.
As for the collector car insurance, check the policy carefully. They are
usually restrictive on how the vehicle can be used. Don't rely on the agent.
Read and understand the contract. Imagine finding out you have no liability
after you get into an accident.
Dennis
-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Greg Baxter
Sent: Sunday, November 09, 2008 9:43 PM
To: vanagon@GERRY.VANAGON.COM
Subject: 2.2 Rebuild Questions
Hi Everyone!
I've been lurking here for a few months now, since purchasing my 87
Syncro Westy in August this summer. I've spent the past month doing
searches and taking notes, mostly The Samba, Shoptalk and here on the
list - just ask my wife how much time I've spent doing the searches...
We took him (Bastian) on a couple of road trips this summer, down the
Oregon coast and through the interior of BC. On the last leg of the
trips, he was pushing exhaust gases into the coolant, suggesting (at the
least) that one of the green rings in the bottom of the cylinders was
shot. This only happens when 'compression braking' down long grades. I
can drive him on flat roads forever, though. Both heads are weeping a
little bit, and he marks his territory with a silver-dollar-sized oil
spot after every drive. Since being parked for a couple of weeks, the
oil spot hasn't grown much, so I guess it's being splashed around while
driving.
Just after purchasing the van, I did the routine tune-up items - cap,
rotor, wires, plugs, filters, oil change, thermostat (replaced the
original from '87) burped the rad. I'm about 3 years away from being
able to use collector plates and saving a ton on insurance, so those are
a couple of reasons that I want to stay with a stock (ish) engine.
I'm up in Canada, eh, and our dollar is on the decline against the US
buck, so for me, the option of buying an engine and having it shipped up
here gets difficult and expensive.
I'll get some pics up soon, but for now - here are my plans and
questions. Please feel free to comment, question and respond as you like.
My goal is a reliable, slightly-more-powerful-than stock,
emissions-passing engine that I won't have to worry about for the next
20 years. Fuel economy is an issue, but not my top priority. I don't
mind using 90 or even 94 if the need be.
My questions are - will this combination work, and what have I
forgotten. I'm trying to keep this whole endeavour under $3500 CDN -
today that's +/-$2950 to those of you in Obama-land.
Here's the list:
GW 2.2l P&L Kit
GW AMC heads - I want to get these ceramic coated - worthwhile?
Scat 5.4 or 5.5 CrMo rods (I get that the small ends have to be
machined to 22mm, will I have to machine the pistons to get the 5.5s to
work?) *Are the weight savings worth the extra $100 over machining my
stock rods?
CB Performance 2252 Cam & Cam gear
CBP Maxi I Oil pump
Engine Gasket set
Oil Pump cover nuts/gasket
Oil Pressure Release Valve & Spring
New Hyd lifters
(CrMo Pushrods?)
Clutch Kit - do I need to go heavy duty?
Main Bearings
Rod Bearings (do I need if I'm going with new rods?)
Camshaft bearings (are these 'always replace'?)
Blue coolant temp sensor (did the black one when I did the thermostat)
Oil Pressure switches
O2 sensor
Fuel lines
What other machining will I need besides the crank? I like the idea of
sending the crank off to Mr. Stamkos, but in the interests of my budget,
can my local machine shop do the work?
A little background about myself - I've been into watercooled VWs since
I bought my first Mk2 Jetta in 94. Since then, I've gone through an 82
Scirocco that I swapped a later engine into, and did a bunch of bolt-ons
to. My current car is a 90 Corrado (digi 1) that's turbocharged. My
mechanic did the wrenching on that project. Because of the Corrado, I
have a decent, basic understanding of Digifant, although I understand
that there are some differences between the Corrado & the Vanagon -
namely the knock sensor, and the availability of aftermarket tuning
options. I work at a greenhouse/nursery during my days (sorry, folks,
only legal plants grown there! Laughing ) and there's not much going on
there this time of year. My time evaporates quickly in February until
June, so I need to have the project finished by, let's say, Valentines Day.
What sort of special tools am I looking at? I've got the basics, a floor
jack, a clean, well-lit 2-car garage, (2/3 taken up by the Westy) but no
engine hoist, stand or workbench. I'll be able to work on it weekends
and evenings. I'll start the teardown next weekend but I'm waiting on
December 1 to order the GW parts in the hopes of a Christmas special.
How am I doing so far, gang?
Many thanks in advance!
Greg
'87 Syncro Westy 'Bastian'
