TES engines bodged 2.2 bigbore rebuild failure

[ajsimmo]

Sorry, I wasn't clear that we do rebuild WBXs to order, as I didn't want it to sound like an advert!
Rebuilds and repairs are done in liaison with the customer, where we will advise what we think can be reused and what should or must be replaced. We can source new, reconditioned or good used parts as required. We build engines according to the owner's brief and budget, with complete transparency, and giving our honest opinion on best practice where required. So it's all down to expectations and budget. We can repair or we can completely rebuild using all new parts, and everything in between, but you'll know exactly what's inside.
There is nothing wrong with rebuilding an engine from used parts, as long as you call it that. We do not paint our engines either, as we believe the beauty is on the inside!
We aren't doing the one I referred to earlier purely because he wants to do it himself, but we are happy to advise as he is an existing customer.

[what2do]

Sorry, I wasn't clear that we do rebuild WBXs to order, as I didn't want it to sound like an advert!
Rebuilds and repairs are done in liaison with the customer, where we will advise what we think can be reused and what should or must be replaced. We can source new, reconditioned or good used parts as required. We build engines according to the owner's brief and budget, with complete transparency, and giving our honest opinion on best practice where required. So it's all down to expectations and budget. We can repair or we can completely rebuild using all new parts, and everything in between, but you'll know exact what's inside.
There is nothing wrong with rebuilding an engine from used parts, as long as you call it that. We do not paint our engines either, as we believe the beauty is on the inside!
We aren't doing the one I referred to earlier purely because he wants to do it himself, but we are happy to advise as he is an existing customer.

Just because of WHO you are, I'd feel confident that a rebuild from you would see me good but at what point does one ask the question 'a tdi may be the better alternative'? I'm not in the market for either option as I've got bugsteve's old engine that i trust to be a good 'un because he worked on it himself. Lots of people come on facebook and 80 - 90 bordering on tears looking for a replacement engine out of desperation which is never the best situation to be in. We need a charitable person who can buy/deal in working engines that isn't adding scene tax.............Capitalism, it'll never work!!!

[AdrianC]

Sorry, I wasn't clear that we do rebuild WBXs to order, as I didn't want it to sound like an advert!

<grin> I was thinking more of an advertised rebuild service aimed at competing with the off-the-shelf boys.

So it's all down to expectations and budget.

Problem is that people focus on budget and believe the over-inflated claimed expectations...

Speaking personally, if I was starting from a diesel van, I'd go 1.9D/TD rather than rebuild. If I was starting from a WBX, I'd stick with a WBX rebuild rather than go straight-four, Subaru or diesel - because I find the WBX an interesting engine.

[Paul Weeding]

Seriously, I wonder if there's room for somebody to advertise rebuilds at "£X plus parts"?

This is essentially how I rebuild engines...

None of this cutting corners... Engine is stripped, everything is checked for wear, what needs to be replaced is...

[bugsteve]

yes, thats right. was my dg.. remember i was in 2 minds to sell it as thought i may need it as a spare at some point.... i just didnt have the space in the lock up for it and the beetle... how you doing anyway, hope you are well!

Ticking along nicely thanks, looks as though my spare (purchased from you) is a lot better than your poorly lump. Could be worse, you could be skint and desperate. Every cloud has a silver lining and all that!

Ps. You've not told us what your plan is with TES.....

just arrived to hamburg, nice reading everyone's inputs... about the plan with TES.... I would quite like to stick that cam in him and see if HE runs smoothly on all four!

[Plasticman]

Course he would if you rammed it hard enough I doubt he could stand lol
mm

[bugsteve]

Blimey, it's spooky reading this. I have a customer who had an almost identical experience with his TES big-bore. It ran rough and rattly, had low oil pressure problems, and never had the power that was promised. He ripped it out and went for a Vege recon, which was also carp and failed. He is now rebuilding it himself because he is a retired engineer and he can, and wishes he'd done that in the first place.
My input is that i did his LPG conversion (and no, it didn't cause either of his two engine failures!), and am now advising him on best suppliers for his engine parts.
Btw, for those who find such things intriguing, he is running Emerald engine management with full sequential injection and dual ignition maps. It was the rolling road session that revealed problems with the Vege, but it went very well on both fuels for a short while!
I'm looking forward to seeing/hearing/driving the finished product (and I'll have access to the maps ).

hmmm interesting.. i wonder who else has had troublesome engines from TES... or who has had bigbore engines that have been fine also for that matter.. for mine it was definitely caused by the top rings being to narrow for the groove, but one thing still puzzling me is the diamond cut out found only in one piston.. these two points boil down to basic neglectful inspection during build imo whereas the cheepo cam and lack of machining to small ends etc is from doing things on the cheap to increase profit margins.

anyway enough of them and on with the new build specs,i am very interested in this dual map sequential emerald injection you speak of. any info you have regarding this gratefully received.. In the first build i retained the pierburg and re-jetted.... so as to keep the lpg.. i would love to put twin 44's on but the miles i do through Europe it would not be practical.. gas is 50p a litre in Czech and not much more in Belgium and Luxembourg.. also running a separate map for gas will give correct fueling throughout the rev range ehh which cannot be achieved well with open loop.. with this in mind before i added a valve saver oiler system.. just to be on safe side

but this time around the punny old pierburg will ave to go!

[bugsteve]

so for the new one, i have ordered everything i will need.. i will put prices besides for info

first off 2235cc pistons and liners from CSP. bigger displacement while retaining 10.1 compression, talked at length with christian at CSP to make sure they are good before ordering and was reassured.... as they come with bloomin hefty price tag! (he even posted them for free as i am a returning customer from 2008, good chap he is) 800euros!

next i called heritage to obtain replacement stretch bolts and small ends to rebuild the rods.. they only had 7 stretch bolts in stock so another very nice guy named Paul in the sales office did me a NOS set with 46% discount! £175 normal price though..

and i ordered top quality gasket set £110 ish i think...

then i looked to ahnendorp BAS for some parts, I chose this..
1 x
Rod Bearing Set VW Wasserboxer Engine -0,25
06025
11,35 EUR
11,35 EUR
1 x
Mainbearing Standard / -0,25 up to 08/1985
05171
95,00 EUR
95,00 EUR
1 x
Cam Follower Hydraulic Wasserboxer also to use with Schleicher hydraulic cams
04735
140,00 EUR
140,00 EUR
1 x
Schleicher Camshaft VW Wasserboxer 292°
04013
285,00 EUR
285,00 EUR
1 x
Exhaust Valves VW Wasserboxer 33,9mm /9mm
09332
119,11 EUR
119,11 EUR
1 x
Intake Valves VW Wasserboxer 39,9mm /8mm
09322
63,66 EUR
63,66 EUR

Subtotal: 714,12 EUR

these guys also do piston and liner kit 2.1 10.5.1 compression which looked good but i went for the CSP,s for the extra 124cc they provide, they also do a range of wilder cams that require solid lifters.

30mm shedek oil pump i already had in garage £30 odd oh but i got a brand new original steel pump cover for £8 and on rebuild will check oil inlet/outlet holes and match them to case if needs be..

i got all 8 journals on crank ground for £60 from banda engineering in Portsmouth

and got some other bits and bobs like filters, spark plugs and oil etc..

My AMC heads are from TES build, but will need new inlet guides at least... i am toying with the idea to send them to stateside for polishing and porting.. undecided if this is really necessary at mo so will have a think and an ask about.

oh and i bought a DTI gauge off ebay for £20 to measure crank end float, cam gear backlash etc..

cant wait to get back in the new year and get it all together now!

[300CE]

Good luck with it Steve & keep the updates & pics coming chap

[silverbullet]

Btw, for those who find such things intriguing, he is running Emerald engine management with full sequential injection and dual ignition maps. It was the rolling road session that revealed problems with the Vege, but it went very well on both fuels for a short while!
I'm looking forward to seeing/hearing/driving the finished product (and I'll have access to the maps ).

I'm in

[Smosh]

I, when it needs doing, will be taking mine to a local engineer. He is also just starting a VW specialist restoration business that is focusing on being affordable. Interestingly there are two other VW specialists in Guernsey! You think you pay scene tax...

[toomanytoys]

Btw, for those who find such things intriguing, he is running Emerald engine management with full sequential injection and dual ignition maps. It was the rolling road session that revealed problems with the Vege, but it went very well on both fuels for a short while!
I'm looking forward to seeing/hearing/driving the finished product (and I'll have access to the maps ).

I'm in

Me too

[bugsteve]

maybe we can get together and all have duel map efi?...... please keep in touch guys..

at least ave a dig about and share the knowledge with everyone..

[silverbullet]

Will do. Could be ideal for my 2500E

[bugsteve]

heres some pics of the installation first time around plus a little lucky find only apparent due to sandblasting and powder coating of inlet manifold... attention to detail and meticulous cleaning and inspection is the only way to go... £2 quid later and a new steel plug... water leak and a partial coolant drain and repair avoided! whats on the inside of the engine is only half the story... all the various bits and bobs have got to be up to scratch as well. needless to say si baxters pension fund is looking rosy and courier guy knows me and my van very well, hes delivered most of it in his crafter!!