Engine Refurb

[feasey59]

Hi guys, I'm a newb, although I have had my van for a few years (I wont bore you all with my sob story) and now I have taken on a little challenge.

Me and my mate are coming up with a plan to cycle from Plymouth to Ibiza for charity, as Im ex military going to be looking at Help for Heros (thats another matter in hand)

Ill cut to the point, my mate has given me till the 6th of May to get the van in a state in which it could be our support wagon, were aiming to leave for the adventure on the 23rd so thatll give me 3 weeks play.

If at all possible, has anyone stripped and rebuilt an engine and have any little hints and tips to help me on my mission. Im looking at the gasket replacement kit, and possibly the top end rebuild kit on VW heritage, Im going to strip before I order as to see what state it is in, but does anyone have any hints on special tools that I may require? I will be reading the manual on the task in hand, but, as from experience, I know full well its not going to go as easily as it is the book.... Or is it?

Any help, links and information will be deeply appreciated and I will be taking as many photos etc and notes to try and spread the love.

Many Thanks

Dan

[Pauly]

Hi. Buy the complete engine gasket kit and some RTV sealant. Use the sealant on all the gaskets and joints except o rings and push rod tubes. I call it double protection as oil leaks are the most common issue when it comes to air cooled motors.

Paul

[feasey59]

Hi pauly,

You seem to be the main man on here. Thanks for you input. I now have the engine stripped and split. No i have gone this far are there any major components, regardless of condition, would you recommend on replacing? Ive marked up the crank and cam shafts and going to take them out very shortly and would appreciate you opinion.

Many thanks

Dan

[Pauly]

Hi again, did you miss your deadline? Things to renew if the case is split are the main bearings, you need a puller to strip the crank. Big ends and cam bearings. To replace the small ends you need to have them honed once inserted. Have a look at the crank and decide if it needs a regrind. When reassembling dont use a double lip crank seal they arent all that. Replace the oil strainer and deffo fit a new oil pump. With all this your bottom end should be solid. You can always rebuild the top end without splitting the crank case at a time that suits you. Have a good trip Paul

[feasey59]

Ah, my mate was ambitious to try and get the training done in 3 months, i did try and tell him this at the time, however, he was very stuborn about it. Ive convinced him to do it in august.

Thats awesome, ill make a list and get on it! I got all the gaskets and sealant in now (as you suggested) and hopefully get on the rebuild soon enough! If i get the crank regrinded, would that mean ill have to get different bearings or will the tolerances be fine?

Many thanks mate.

[Pauly]

You will need oversize bearings