Date: Sun, 9 Nov 2008 23:10:57 -0500
Reply-To: Jim Akiba <syncrolist@BOSTIG.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Jim Akiba <syncrolist@BOSTIG.COM>
Subject: Re: 2.2 Rebuild Questions
In-Reply-To: <49179FB1.9050706@shaw.ca>
Content-Type: text/plain; charset=ISO-8859-1
Looks like a good list for engine mechanicals, but you're completely
leaving out the engine management side of things which is very common
when putting together this sort of project. Even assuming you could
get 20 years out of the rebuild(I would say that's a bit optimistic
honestly lower your expectation to 5-10 and you'll be much happier) if
you're wiring, sensors, and controls aren't also addressed I guarantee
you won't get anywhere near that figure for longevity on the engine.
You should consider what it is going to take to also bring those
aspects of the repowering into the picture, and make certain they are
all functioning to spec and will stay that way for as long as you want
them to, as without it your weak link will be engine management, and
endanger the entirety of your efforts. The three links are engine
mechanicals, engine management, and operator information. Any one weak
spot in any of those three links can ruin your chances of achieveing
your goals in short order. I wish I could offer you more specifics on
just what you need to consider in this regard, but there are others
far better acquainted with the bosch setup that you should be looking
to for input. Also keep in mind the old car-guy addage: Fast, Cheap,
Reliable, pick two.
Jim Akiba
On Sun, Nov 9, 2008 at 9:42 PM, Greg Baxter <gregbaxter@shaw.ca> wrote:
> 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'
>
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