Date:         Wed, 8 Sep 1999 16:02:02 -0700
Reply-To:     Björn Ratjen <bratjen@DIRECT.CA>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Björn Ratjen <bratjen@DIRECT.CA>
Subject:      waterboxer overhaul
Content-Type: text/plain; charset="iso-8859-1"

Hello Volks,

I am currently overhauling a 2.1L Waterboxer with 280000kms. It's for a
friend who is a mechanical newcomer but owns a Syncro crewcab. The engine
is completely apart now and the core of the engine including main bearings
look really fine. I will replace them anyway. Camshaft and bearings are
alright as well. Pistons and cylinders still measure up. I will replace
rings. Piston pins are not easy to remove due to the high sidewall of the
block. Tip: I used a 6" long 3/4 bolt removed the clip on the more
accessible side (through hole), stuck the bolt through, put a nut on the
open end that fit through the clip and pulled the pin out hammering against
an adjustable wrench placed before the head of the bolt: cheaper than VW
tools. 

The heads need the usual work with resurfacing and new valves. The
resurfacing might increase compression slightly. We might go for new heads. 

The engine should last a long time. Two questions remain.

1. What should be done as corrosion prevention? 
(grounding straps?, insertion of kathode? special gasket sealer?)

2. What can be done to improve performance?
(larger valves? different camshaft? 
or: Kompressor also called blower to precharge intake air, would Digifant
recognize and adjust mixture through O2 sensor, any experiences?)

Let's see what we come up with to make the waterboxer more lasting and more
efficient. 

Björn


Björn Ratjen
Mill Bay, B.C.

1987 Vanagon est alia (self camperized)
1978 VW Bulli (self camperized)
1995 Passat TD Wagon (hers)
1970 VW Beetle (son's)