Engine rebuild (2000cc CU)

[dandan1234]

Evening folks
I have recently taken my T25 out of winter storage. I changed the oil and filter which i normally do at the start of the season.
To my horror i discovered small metal pieces in the oil!

Obviously something serious had happened, so i decided to remove the engine and strip down to investigate.

Engine out, took me 2 hours on my own.


Onto the bench.




cases split.


This is where the small peices of metal have come from. Picked up on centre main bearing.


cam is shot too.


cleaning up various parts whilst waiting for the crank to be reground.


So far the heads, valves, pistons and cylinders look ok, still a very long list of parts to buy.
Can't believe the price of some type 4 parts!

Will keep updating this thread with my progress.

Any tips/experiences from anyone who has rebuilt one of these much appreciated.

Thanks Dan

[Plasticman]

no advice as i assume you know what your doing but keep plenty picks coming as it makes good and informative reading
mm

[volks_womble]

Great pictures. Have a horrible feeling mine is going to need this treatment, so please do keep the pictures up

Thanks
Mark

[dandan1234]

Thanks, I'm really lucky to have a fully equiped workshop to do it in, as I'm a HGV fitter.

These Aircooled engines are new to me though!

[Plasticman]

Sad that you have to play with foolsfuel rather than propper derv
mm

[BOXY]

Once you've finished practising on yours I'll run it in for you for free in my van, and you can have my engine to keep learning with. How does that sound.

[937carrera]

I'm interested to know what you are going to do with the camshaft.

Interesting, and a little surprising for me that it seems to wear on the lift / base circle portions rather than the cam lobe itself

Good luck with the rebuild. i might be in the same boat so which bits are you finding expensive ?

[dandan1234]

Everything seems expensive compared to other engines fitted to these vans.
Just priced up most things i need and looking at around £800 and i'm by no means replacing everything!

[paulandchez]

Don't know if you're aware, but Coolair have 10% of EVERYTHING this Saturday 18th April on orders over the phone or online. I know as they sent me the flyer in the box of £600 bits I got off them last week!!!!!

I'm just rebuilding mine and was going to add a post too (already running it on another forum so was going to copy and paste for anyone who might find it useful)

[dandan1234]

Thanks for that, was going to get most of the bits from them.

[dandan1234]

Well most of my parts are on order now.
Can't seem to find a standard oil pump. Does anyone know where to buy them new?
Thanks Dan

[937carrera]

It's a good question. I spent a bit of time looking round last night trying to find a source as i would want one if I have to do a rebuild. I didn't find any either.

[CovKid]

You may struggle finding stock ones: https://www.vwheritage.com/shop/bay-bus ... earchType=" onclick="window.open(this.href);return false;

[937carrera]

..... or perhaps this http://www.scatvw.com/master/oil_pumps/

Looks like new ones are no longer available http://ronleclerc.net/engine04.html

[dandan1234]

Thanks for the links guys, have done some reasearch already on these aftermarket heavy duty pumps.
And lots of people are saying that you can get problems with the higher pressure. As it can open the pressure relief valve and bypass the cooler resulting in over heating.