Date:         Sat, 18 Dec 1999 19:24:30 -0600
Reply-To:     John Rodgers <inua@SCOTT.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         John Rodgers <inua@SCOTT.NET>
Subject:      Engine Rebuild at Last!!
Content-Type: text/plain; charset=us-ascii

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