Date: Sat, 18 Dec 1999 20:57:02 -0600
Reply-To: John Rodgers <inua@SCOTT.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: John Rodgers <inua@SCOTT.NET>
Subject: Re: Engine Rebuild at Last!!
Content-Type: text/plain; charset=us-ascii
A couple of more comments on my engine teardown. The cylinder barrels were
marked with what I took to be Audi markings. Each barrel had the four
overlapping circles that are audi marks. Can anyone explain that to me.
Also, to Ken Wilfy, having to take the engine down this far( split case, new
mains, etc) it's going to get new barrels, pistons, rings, piston pins, and
rebuilt rods, as well as a complete balancing job.
My mechanic, a man with eons of experience with aircooled VW engines, said
its #3 on them that always goes as well. Makes me wonder about the flat four
design all the way around. I had planned an extensive rebuild with lots of
mods, but I'm not going to bother. Looking at the way this failure occurred,
and the pattern of failure in so many others, this puppy is going to get a
different engine sometime out in the future.
John Rodgers
John Rodgers wrote:
> Finally, after weeks of waiting, the rebuild of my 2.1L from my "88GL is
> underway.
>
> I have STILL not decided whether to simply order and engine, send this
> one out for overhaul, or have a local mechanic do it.
>
> I did have a trusted mechanic the engine, and because I really wanted to
> see what the internal failure was that brought the van down, I had him
> go ahead a pull the heads and cylinders. I wanted to have a good look.
> After all, this engine was the original that came in the vehicle, and it
> failed without warning at 78,000 miles.
>
> Heads: Except for normal wear on the valves, both heads were in
> excellent condition. There was absolutely no evidence of corrosion
> anywhere. The mating surfaces were all as clean as a whistle, and the
> original machining marks were still present. There was no evidence that
> the cylinder failure had caused any valve or head damage. A clean up and
> a performance valve job with new valves and guides and they will be as
> good as new.
>
> Cylinders: The cylinder that failed (#3) is the one forward, closest to
> the driver on the driver side of the vehicle, and .....as seen from the
> rear of the van...#3. Inspection of this cylinder and piston revealed
> evidence of overheating. There was no hole in the piston as originally
> suspected, but instead a burned place on the piston edge toward the
> driver. A piece of the piston was missing at that point, as well as a
> piece of the top ring at that point. The side of the piston was galled
> severely with pieces of piston torn away. The cylinder barrel was
> severely grooved with multiple grooves on the pistons burned side.
>
> Cylinder #1 had a fouled plug and showed other evidence of oil fouling,
> indicating severely worn rings or eminante failure or that cylinder
> also. The head for this cylinder was in good condition except for the
> residue of burnt oil. The cylinder barrel was in excellent condition,
> with no evidence of barrel ware. All the crosshatching in the barrel was
> intact with no evidence of wear. The barrel is considered by the
> mechanic to be reuseable after the barrel glaze is removed.
>
> Cylinders #2 and #4 were the same as #1. All crosshatching was intact
> and no evidence of wear. Very re-useable.
>
> It was very evident even in this stage that metal had gone through the
> system. I think that on Monday I will have the case split and examine
> the internals for damage. After that, I will decide how to proceed.
>
> When I started out on this journey I had planned to follow Robert
> Lilley's example an rebuild mine as he did his. I have changed that plan
> a bit. Will keep the list posted as to progress on this project.
>
> John Rodgers
> "88GL owner
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