(7/19/2002) - Got some more parts in!
These are my new zinc plate pushrod tubes. My old ones were zinc plated also, but last time I had the engine apart, I had to replace a couple bent tubes (with a different type) - so they no longer were a matched set. New ones are cheap, so might as well make it all match up!
This is my new breather. I will eventually be installing a sand seal (and machining the pulley for a steel collar), which means I need to be sure to have the engine vented. I will weld in some vents to my valve-covers, that way I will have a hose running from BOTH valve-covers AND the oil filler tower. You can see it installed in the 2nd pic (that other 'box' is my CDI).
Instead of using the wimpy stock 'wire' wrist pin keepers, I will be using these tru-arc keepers.
There should be enough seals and gaskets here to keep the engine from leaking :-)
The new engine cases DONT have a groove for the standard cam plug, so you have to use a non-grooved rubber cam plug like this:
These are so cheap I sometimes wonder why people use the old stuff. This is the bakelite spacer that goes between the fuel pump and case (the old ones always crack/break).
New sealing nuts for the oil pump, and case.
This is the engine case install kit - it comes with the type 3 blockoff, new pistons for the oil relief ports in the case, some studs, it also comes with new springs, but DONT USE THEM! They have the wrong stiffness.
The case install kit comes with a NEW type of oil relief plug! Instead of having to use a HUGE flat-blade screwdriver (we all know how big of a pain that is), you can just use a socket wrench:
The filter kit is still on the way here, but here is the type of filter I will be using.
This is a 2 GRAM (that's small) container of "quick seat powder" - You rub it in to your cylinders before you install, and it helps break in your rings. If you open the lid, DONT SNEEZE, OR MAKE ANY SUDDEN MOVEMENTS or you might need some more LOL!
These are my new Brazilian lifters.
This pic isn't very good, but these are new Weber pump jets (for my carbs). Webers come with a "55" pump jet from the factory - the original jets only send some gas to the accelerator jet and bypass the rest. These are "0" pump jets, and send ALL the gas to the accelerator jet. This should reduce some hesitation.
These are my new bearings. MAHLE all the way! The cam bearings are double thrust in standard size, the main and rod bearings are .010" over since my crank has been cut once. (The new case IS NOT line bored!)
AND HERE IT IS, the new case (the 'rusty' looking junk you can see is just the dried cutting fluid used when the case was machined - I haven't cleaned it up yet):
For those who are curious about all the specs on the case, I can tell you firsthand this case is PERFECT. The case just needs to be cleaned and deburred. The measurements I made of THIS case are in the table below:
|R. Case-Half Lifter Bores (viewed from oil pump)||Lifter Bore Measurement||Proper Bore Size (According To The Bentley (Official) VW Service Manual)|
|L. Case-Half Lifter Bores (viewed from oil pump)||Lifter Bore Measurement||Proper Bore Size (According To The Bentley (Official) VW Service Manual)|
|Cam Bearing Bore (viewed from flywheel)||Cam Bores||Proper Bore Size (According To The Bentley (Official) VW Service Manual)|
|Main Bearing||Bearing Bores||Proper Bore Size (According To The Bentley (Official) VW Service Manual)|
|Flywheel Oil Seal Bore||Proper Bore Size (According To The Bentley (Official) VW Service Manual)|
|Oil Pump Bore||Proper Bore Size (According To The Bentley (Official) VW Service Manual)|
For the past few days I've been cleaning up parts, inspecting parts and measuring parts. I have drilled and tapped the case (in preparation for cleaning AND a full flow filter) - I WILL have a tech article of the entire thing up sometime... Right now I am just waiting on a handful of parts so that I can get this engine back together (the parts should be here in a few days!). For those who are curious: once I get my piston rings, I will take my crank, flywheel, bearings, rods, pistons, and clutch pressure plate to the machine shop to be balanced. Then once I get my cam, straightcut cam gears, pushrods, and full flow filter kit it will be time to re-assemble!
by Eric Huelsmann