Engine rebuild

[yeti]

1.9 Dg with 92k on the clock. I have an oil leak and back box joints blowing now and then. I,m willing to drop the lump out and strip down to the bar bones. replace all my seals and gaskets etc and rebuild. tappets are a bit rattley and i'm wondering
(a) do i just soak clean and replace tappets
(b) replace tappets
(c) is there a better book then the haynes to use for a guide bolt torque etc
Is there anyone that has done a complete rebuild with new gaskets and seals and has it made a different. I will do a de-coke at the same time

[toomanytoys]

where is the oil leak and how bad? Most have a leak or 2... and unless its pouring out.. not worth the hassle.. and cost..

Have you rebuilt an engine before?

To be fair by the time you have stripped it and rebiult using new bearings etc as well.. you'l be nearly into as much cash as a rebuilt exchange engine... and the van will have been off the road for a while..

[kevtherev]

De coke ...I haven't heared that in a long time nor would I expect your engine needs it

Hydraulic lifters are available from VW.
I would not be opening anything that does not leak... can of worms waiting for you there
get all the parts first...

oils seals from VW, likely ones are the crank pulley seal and the one behind the flywheel (be careful with the end float shims)
push rod tubes I think you can re-use them, they come with seals too.

after you have removed the vave train keep it all in order.

seems a lot of bother for a tappy engine that may just need an oil change and the tappet lash reset
where's the leak from?

[yeti]

oil leak looks to be from push rod tubes, yes i have built engines in the past but not a boxer before.

[ghost123uk]

Have a read of this post = https://club8090.co.uk/forum/viewtopic.php?f=2&t=52374" onclick="window.open(this.href);return false; - it is along one but well worth reading if you are contemplating a strip and rebuild.

[kevtherev]

oil leak looks to be from push rod tubes, yes i have built engines in the past but not a boxer before.

like you I have built many engines before but never an engine where spares are at best scarce..
getting your spares first is good practice.

Removal of the head should be last resort with DG's, head stud failure can be expensive and time consuming.

[fix]

If you dont really need to do it then dont!

Im still putting mine back together, been at it for ages. Waiting for parts, asking for advice, it's all taken a long time.

Things are getting there, but if you dont really need to strip it i wouldnt bother.

[toomanytoys]

You dont ned to strip and rebuild to sort a leaking pushrod tube seal.. get an expanding one/s (yes they are costly) and only disturb the one/s that is/are leaking.. no need to disturb lifters...
unless it peeing out.. leave it till it gets worse...