rebuilding motors

2,457 posts · joined Jan 2004 · 17 Nov 2005, 1:07 pm

#429675

is there much involved in rebuilding a vdub motor?
I have never attempted this myself but curious as to the difficulty etc

see.... air and water do mix 😉

1974 1300
1997 MK3 Golf GL
2003 NB Cabrio
2012 Golf VI GTI
2014 Audi A4 Quattro

VWFREAK VWFREAK

2,577 posts · joined May 2004 · 17 Nov 2005, 1:28 pm

#429688

Buy a vw manual and start 1 page at a time. There's quite a bit involved in my opinion, so get a mate to give you a hand if he has the know how. Thats how I started out.

helbus Administrator Mad fabricator, paint and body

7,386 posts · joined Sep 2002 · 17 Nov 2005, 1:30 pm

#429689

I found that using two manuals was more beneficial. I used the Gregory's workshop manual and the Muirs Idiot book. I found that whn one could describe it better, the other would hava photo, and the workshop one tended to have more of the torque settings and other specs.

This was on an 1800 type 4 motor.

EJ22 into Bay Microbus - Finished project build thread- click on this spot here for info

blutopless2 DAMSLO

2,457 posts · joined Jan 2004 · 17 Nov 2005, 1:37 pm

#429695

So i take it that it is not just a simple bolt on process with the barrels and pistons?

see.... air and water do mix 😉

1974 1300
1997 MK3 Golf GL
2003 NB Cabrio
2012 Golf VI GTI
2014 Audi A4 Quattro

helbus Administrator Mad fabricator, paint and body

7,386 posts · joined Sep 2002 · 17 Nov 2005, 1:43 pm

#429700

Not really that simple. There are pushrod tubes and seals, tinware, manifolds, gaskets, all have to be cleaned, faced, make sure they are all servicable etc. If you have any sort of service manual at the moment, or one you can borrow and read, it will give you much more of an idea of what is involved.

EJ22 into Bay Microbus - Finished project build thread- click on this spot here for info

PurpleT3 Fahrvergnugen

880 posts · joined Apr 2003 · 17 Nov 2005, 2:47 pm

#429734

I would suggest a book called How to Rebuild the Volkswagen Aircooled Engine by Tom Wilson. It is quite an old book, but it covers all models and types of engines. I bough mine from Amazon http://www.amazon.com/gp/product/0895862255/104-9093965-0091100?v=glance&n=283155&n=507846&s=books&v=glance
It is quite thorough and covers all the details. This, in conjunction with a service manual specific to the model should tell you all you need to know.
How far you go is up to you. You migh just want to do a top end freshen up, or do the pistons & barrels as well or go all the way and rebuild the whole thing. It is not all that complicated, but there are many hours of work involved, hence the high cost of buying a rebuilt engine.

Ain't nothin' like the wind in your hair.

blutopless2 DAMSLO

2,457 posts · joined Jan 2004 · 17 Nov 2005, 2:52 pm

#429737

thanks.

see.... air and water do mix 😉

1974 1300
1997 MK3 Golf GL
2003 NB Cabrio
2012 Golf VI GTI
2014 Audi A4 Quattro

Bizarre Moderator The artist formerly known as blue74l

12,787 posts · joined Aug 2002 · 17 Nov 2005, 4:49 pm

#429781

depends what you call rebuilding

A top end rebuild is pretty easy.

New pisons and barrels, refurb the heads, check deck height, set compression ratio, new seals, set/check rocker geometry ( :duh ) bolt back together.

It is the bottom end that gets harder.
line boring cases, thrust cutting bearing faces and bearings to suit, setting end play

here is something of an over view for you

http://www.vw-resource.com/engine_rebuild.html

Also there is a wealth of information on the engine rebuild forum on Shoptalk.

http://www.shoptalkforums.com/viewforum.php?f=34&sid=7e413be45e9abc6d796590bd404b67c6

A whole section just for rebuild questions.

Futue te ipsum!!!

shiftyvw Wolfsburg Wizard

523 posts · joined Sep 2002 · 17 Nov 2005, 5:06 pm

#429789

VW motors arnt any easier to build than any other engine in my opinion. a bit trickier in many respects, especially if you dont want oil leaks. If you wouldnt attempt to rebuild another type of engine a VW is no easier. Why do you think your motor needs rebuilding?

testing 1 2 3...

blutopless2 DAMSLO

2,457 posts · joined Jan 2004 · 18 Nov 2005, 8:09 am

#429962

thanks bizarre that made for a good read.. gives me more of an understanding of the things involved with rebuilding.

see.... air and water do mix 😉

1974 1300
1997 MK3 Golf GL
2003 NB Cabrio
2012 Golf VI GTI
2014 Audi A4 Quattro

blutopless2 DAMSLO

2,457 posts · joined Jan 2004 · 18 Nov 2005, 8:10 am

#429963

shiftyvw wrote:Why do you think your motor needs rebuilding?

I dont.. just curious as to the amount of work involved and whether it can be done by a mechanically minded person etc... or whether its best left to the pros.

see.... air and water do mix 😉

1974 1300
1997 MK3 Golf GL
2003 NB Cabrio
2012 Golf VI GTI
2014 Audi A4 Quattro

HEL-70Y Officially Full-On Dubber

247 posts · joined May 2005 · 18 Nov 2005, 8:19 am

#429966

me and my mates were going to re-build mine but after talking to a bunch of people, the bottom end seemed a little difficult, of how everything has to be precisley spot on and if its not you will have some problems. Also i found that the right combination to be very important and people not willing to give out there combination. So i built up the top end my self then pulled out my engine stripped it down to the pistons and then gave it to a mechanic, cost a bit but i thought id be better off, also the 1yr warrenty is good...no headachs this way

Before you judge someone, you should walk a mile in their shoes. That way, when you judge them, you're a mile away and you have their shoes.

shiftyvw Wolfsburg Wizard

523 posts · joined Sep 2002 · 18 Nov 2005, 4:50 pm

#430130

if your mechanically minded and know how to measure things you can just send the case to someone for lineboring or whatevers neccesary.

testing 1 2 3...

ugabuga Learner Dubber

5 posts · joined Oct 2005 · 20 Nov 2005, 12:14 pm

#430553

I saved my engine rebuild for the very last part of my restoration. That gave me plenty of time to study several shop manuals (I have 4), read just about everything I could find on www.shoptalkforums.com, and review the bugme videos. It is something a begginner with the necessary tools can do. But, you have to be willing to pay attention to detail, take your time, and never force anything. I highly recommend the book that PurpleT3 offered up as it it seams to be the most comprehensive and has a very logical format..although I did find a few minor things in it that I consider wrong. If you are serious, you should also consider purchasing the definitive Bently manual. The Haynes book is also very good.

Most of all--have fun--or get someone else to do it.

Markley

68beetle Casual Dubber

49 posts · joined Dec 2004 · 21 Nov 2005, 10:24 am

#430801

I'll put in a quick word for the bugme dvds also - just about to start on a rebuild myself with the book that PurpleT3 mentioned as a guide. I've got an old DVD player and TV in the shed and plan on just working through the bugme dvd bit by bit and cross-checking it against the book. The best thing about the DVD's is they show you how to get things apart (rather than just telling you to get things apart like most books). He shows more than one method of separating pieces in most cases also, depending on what tools you have available.

My brother's a mechanic and watched some of the engine rebuild DVD with me and was very impressed - said he wished he had something as detailed as that to help him with the engines he rebuilt while at TAFE.

HotRodMatt If it\'s old or rare - cut it!

3,616 posts · joined Sep 2002 · 21 Nov 2005, 11:45 am

#430822

HEL-70Y wrote:me and my mates were going to re-build mine but after talking to a bunch of people, the bottom end seemed a little difficult, of how everything has to be precisley spot on and if its not you will have some problems. Also i found that the right combination to be very important and people not willing to give out there combination. So i built up the top end my self then pulled out my engine stripped it down to the pistons and then gave it to a mechanic, cost a bit but i thought id be better off, also the 1yr warrenty is good...no headachs this way

You did the top end or the tinware?

Pretty sure I saw your engine on the stand witht he barrells, pistons and heads on it before delivery...

HEL-70Y Officially Full-On Dubber

247 posts · joined May 2005 · 23 Nov 2005, 12:55 pm

#431499

HotRodMatt wrote:
HEL-70Y wrote:...So i built up the top end my self then pulled out my engine stripped it down to the pistons and then gave it to a mechanic, cost a bit but i thought id be better off, also the 1yr warrenty is good...no headachs this way
You did the top end or the tinware?

Pretty sure I saw your engine on the stand witht he barrells, pistons and heads on it before delivery...

sorry i lie. i did the easy part,pulled the engine out, carbi's, alternator and yes tin-ware. what more do u want from a boy that works in an office. I meant in the previous post that i stripped it down up until the pistons. Not sure what you guys class as the top end

[ Edited on 23/11/2005 by HEL-70Y ]

Before you judge someone, you should walk a mile in their shoes. That way, when you judge them, you're a mile away and you have their shoes.