Date:         Tue, 2 Dec 1997 20:58:51 -0500
Reply-To:     Karen Olson <kdosmm@WORLDNET.ATT.NET>
Sender:       Vanagon mailing list <Vanagon@Gerry.SDSC.EDU>
From:         Karen Olson <kdosmm@WORLDNET.ATT.NET>
Subject:      Fw: 84 Starter/Auto Trans problem?
Content-Type: text/plain; charset=ISO-8859-1

----------
> From: Karen Olson <kdosmm@worldnet.att.net>
> To: gsker@lenti.med.umn.edu
> Subject: Re: 84 Starter/Auto Trans problem?
> Date: Tuesday, December 02, 1997 8:54 PM
>
>
>
> ----------
> > From: Gerald Skerbitz <gsker@lenti.med.umn.edu>
> > To: Karen Olson <kdosmm@worldnet.att.net>
> > Subject: Re: 84 Starter/Auto Trans problem?
> > Date: Tuesday, December 02, 1997 12:16 PM
> >
> > On Tue, 2 Dec 1997, Karen Olson wrote:
> > > With the help of this list I rebuilt my 1.9L 1984 Vanagon GL engine
(my
> > > first engine rebuild experience, unless you count COX gas powered
model
> > > airplane motors at age 13).
> >
> > What did you do to it?  Main bearings, pistons, heads?   What all did
you
> > replace/machine?
> >
> Gerry,
>
> I dismantled everything and checked for wear per Bentley.
>
> The camshaft lobes and bearings had the most visible wear. I installed a
> remanufactured cam and new camshaft bearings.
>
> The valve lifter surfaces that mate with the camshaft lobes were also
worn,
> though less obviously.  New ones have a slight convex surface, mine were
> worn level, and I replaced them with a new set.
>
> I put in all new main crankshaft bearings. I had a (backwoods literally)
> shop with a press remove the cam gear from the crankshaft to replace the
> main bearing behind it ($7).  I reinstalled the cam gear at home after
> replacing that main bearing.  The gear slid back on surprisingly easy
after
> heating it up.
>
> I put in new piston rod bearings and piston rings.
>
> I replaced the other smaller crankshaft gear (brass?) that turns the
> distributor and added crankshaft shims to get crankshaft endplay within
> spec (so ignition timing doesn't drift with the excess play).
>
>
> After focusing on rebuilding anything inside the crankcase solidly, I
> wanted to see if the engine would run before investing too much $ on the
> heads.
>
> I cleaned up the heads, and removed the valves and lapped them with a
Sears
> Craftsman lapping tool and compound.  I bought a complete engine rebuild
> gasket kit that included new metal rings for between the mating surfaces
of
> the cylinders and the head, and o-rings that mate the cylinders with the
> crankcase.
>
> A mechanic at VW recommended Curil K2 sealing compound (German), which I
> used throughout.
>
> I hope this helps,
>
> Scott Maurer