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Date:         Thu, 8 Oct 1998 20:20:42 -0400
Reply-To:     EMZ <vw4x4@FYI.NET>
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         EMZ <vw4x4@FYI.NET>
Subject:      Re: Engine Rebuild
Comments: To: Robert Lilley <vwvanman@MAILEXCITE.COM>
Comments: cc: Vanagon@VANAGON.COM
In-Reply-To:  <EDCHBIGGIMGOBAAA@mailexcite.com>
Content-Type: TEXT/PLAIN; charset=US-ASCII

Other than the high life rockers, I have done most of this to my 2 Wheel drive Vanagon. IT FEW! Your on the right track! REmove the Cat and adjust the timing. NO need for a SWAP!

Eric 86-VW4x4 vw4x4@fyi.net 72-240z Pittsburgh, PA USA 1936-Chrysler

On Thu, 8 Oct 1998, Robert Lilley wrote:

> To those that want to have more power, but do not want to do a engine swap, but are in need of a rebuild soon... > > I am in the process of rebuilding my 88 2.1L Wasserboxer. > > I had planned to only do a head gasket repair, but with the death of my transaxle I have decided to do a full engine rebuild with some improvements. > > Here are the improvements: > > 1) Full engine balance- all rotating parts as a unit. > 2) Match port the intake runners to the intake opening.(The runners ID was about 2mm smaller than the intake opening ID- to improve flow) > 3) Clean up the welding on the exhaust system flanges at the head (My new exhaust had welds that restricted flow). > 4) Matched port the exhaust elbow and the twin pipe inlets. (My ports were off center about 5mm off on one side of port) > > 5) CB Performance solid rocker arms. > 6) CB performance 9mm Rhino rocker swivel feet. (Stock are 10mm but not swiveled) > (The feet are the same as 911’s and keep the valve stem guide wear down when increasing the lift) > 7) CB Performance 1.25 Ratio rockers. > 8) CB Performance cut to fit HP push rods- (to avoid having to shim the rockers > > *The 1.25 rockers are the same as FGA is selling. They cost under @$150 from CB Performance. > > I am using cut to fit push rods to eliminate the need for spacers under the rockers and maintain correct geometry. > > > 9) CB Performance Copper 1.5" exhaust gaskets > 10) Chip upgrade > 11) Bosch triple electrode plugs > 12) Mild porting on Cylinder heads- to clean up rough casting, match all ports to same size > 13). K&N Air Filter > 14) Off set grind crank 2mm > 15) LIFETIME warranty Super Turbo muffler ($58) > 16) Rebuild heads with combustion chamber re-shaping to improve flow. > 17) Sanded smooth throttle body casting roughness > 18) Have the sealing surface of the head anodized to keep from pitting out > (I have to do more research to see if it is possible and if it will really work) > > > All of the parts used in the rebuild will be > 1. German (except where none exist) > 2. Cleaned 4 times, they will be polished to remove all traces of any foreign matter. > > *I have done all the porting/sanding/grinding with my B&D Wizard (I wish I had one on my previous engine rebuilds) > A tool like this is handy. > I will be done in about 6 weeks, I’ll keep those interested with up dates > > VWVanman > > > Free web-based email, Forever, From anywhere! > http://www.mailexcite.com >


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