Date:         Mon, 16 Dec 1996 17:31:45 +0000
Sender:       Vanagon Mailing List <vanagon@vanagon.com>
From:         Scott Maurer <smaur@worldnet.att.net>
Subject:      Re: need advice re: rebuilding 84 Vanagon engine

At 10:42 AM 12/16/96 +0000, you wrote:
>     My winter project is to rebuild a 1984 Vanagon engine to 2.1L specs and
>put it into a 1985 Vanagon.  I have rebuilt air colled VWs but not
>wasserboxers.  
>
>     Where do I get a copy of the Bentley Manual everyone is talking about?

     I found mine at a local (Portland, OR), German auto parts store for $64.

>     Does anyone know anything about sandblasting the heads using plastic
>pellets instead of sand, and then coating the heads with enamel top keep down
>the electrolysis corrosion that occurs between the block and the heads?

     After a final cleaning with 99% Isopropyl alcohol (I used this because
it is relatively residue free) I applied J.B. Weld to any pitting as
described in the archives.
 
>     Do I need any special tools to take the engine apart and put it back
>together?  I heard someone say that a special tool is needed to get the
>pistons out but I don't see how that would be necessary if you are going to
>split the block.  Am I right?

     I removed the rods from the crankshaft with pistons attached and
pounded out the piston pins with a "wood dowel rod."
     I do recommend having the cam gear removed from the crankshaft by
someone with a press.  I rebuilt from 2 damaged 1.9L engines and tried 1 cam
gear with a Sears gear puller and after hours of effort, damaged the cam
gear teeth getting it off.  I took the other crankshaft assembly to an
independent VW shop that charged $5 to remove it.
     This was my first rebuild.  So far, I have 800 miles on my results.

Scott Maurer
'84 Vanagon GL 

    I will have other questions later, but these are my initial ones.  Thanks
>for any help.
>
>Russell Gunter
>
>79 SuperBeetle Conv
>85 Vanagon
>93 Eurovan
>