Date:         Sat, 23 Sep 2017 13:49:25 -0700
Reply-To:     Neil N <musomuso@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Neil N <musomuso@GMAIL.COM>
Subject:      Re: Engine Removal. Van Height Double Check Please
Comments: To: Don Hanson <dhanson928@gmail.com>
In-Reply-To:  <CAHTkEuLyDV4g-CJqYSJe_jxb7QNB0A-rumyxTNU+BgVQ9FhS0g@mail.gmail.com>
Content-Type: text/plain; charset="UTF-8"

This ABA I rebuilt was free (280K KMs ??) runner so at the time, cost
wise, I figured a rebuild was warranted and I wanted to gain
knowledge, so I dove in. I checked what I could at home (potential
head warpage, cracked, block bores etc) then had block checked and
honed by a machine shop. They gave the head a passing grade though
there is a little play at valve guide to stem. New valve seals were
installed by shop. I installed new pistons, Grant rings, all bearings,
all relevant bolts. Crank and cam looked ok, I double checked bearing
clearances with Plastigauge after I got all back from machine shop.
All was within spec. I re used the con rods as-is. IIRC, these were
the pistons and rings I installed:

http://techtonicstuning.com/main/index.php?main_page=product_info&cPath=2_13_61_227_228&products_id=2192

Shop installed new frost plugs and galley seals. And of course I
installed and will install all new gaskets. Flywheel, clutch will be
new. If you find a core to rebuild, be vigilant about bore quality. A
flaw showed up on one bore after shop inspected and gave passing grade
to bores, then honed them. I'm not really "buying" that though. But
then I was into them for money at that point so whatcha gonna do eh?
After all was said and done, I think it's far more cost effective to
find a used running known good engine then freshen that up. One could,
at very least, renew the con rod bearings while doing the oil pan
swap. That said, the ABA is an old engine now. Then again, check this
"reconditioned" long block ABA:

http://www.qualitygermanautoparts.com/index.php?p=p1281768556&navt=1993-1998%20VW%202000cc%20Gas%20Engines%20MK3

But then you'd end up with a bump in your engine lid.     ;^)

I"m sure there's a lot I'm forgetting, this rebuild has happened over
last year, but what sticks in my mind is make double sure you find a
reputable honest machine shop and know which tech is doing the work.
i.e. how much experience he has. In my case, I"m pretty sure my
rebuild won't end up being a "smoking clattering boat anchor" but who
knows.

Links to a bunch of random images of "free" ABA, rebuild etc. The
images are typically less than 150 kb each so page should load
relatively quick:

https://goo.gl/photos/8sgVXp8JzKk3dVRg6

https://goo.gl/photos/ZH8dVBqfMYsCVTwT8

https://goo.gl/photos/A7sJ8Uczh2mQRRhJ7

https://photos.app.goo.gl/lFTj2w2YJmcybWz53

IF you're super bored, a big read here about "hone or bore" that I
started. There are images of bore flaw etc. there.

https://www.thesamba.com/vw/forum/viewtopic.php?t=665847&highlight=aba+rebuild

Neil.

On 9/23/17, Don Hanson <dhanson928@gmail.com> wrote:
> I'd like to know what you did to that motor... I'm going to be needing
> another one by and by... I'm considering, deciding between rebuilding the
> 93 àba I have now, or just buying another used jetta... They're remarkably
> inexpensive and plentiful...but it'd be nice to know the motor is in top
> shape...
>

>> -----Original Message-----
>> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
>> Of Neil N
>> Sent: Saturday, September 23, 2017 10:41 AM
>> To: vanagon@GERRY.VANAGON.COM
>> Subject: Re: Engine Removal. Van Height Double Check Please


>>
>> New engine is a rebuilt by me Jetta 2.0 ABA at 50º.

-- 
Neil n

Blog: Vanagons, Westfalia, general <http://tubaneil.blogspot.ca>

1988 Westy Images <https://picasaweb.google.com/musomuso/New1988Westy>

1981 Westfalia "Jaco" Images, technical <http://tubaneil.googlepages.com/>

Vanagon-Bus VAG Gas Engine Swap Group <http://tinyurl.com/khalbay>