912e Engine rebuild, status!
 

This all began last October, the car had started using a fair amount of oil and beginning to sound very lose!!

Removing the engine was pretty easy, I've had my fair share of aircoolers in the past so it was familiar ground.

Once removed, I stipped the engine down to a short block also removing the heads for inspection.

From there I took it to a local engine builder who had a history with VW rebuild, I'm yet to find whether its a good or bad history!

I've stepped up to some KB 96mm pistons with original barrels machined to suit, an unknown sportier cam, all new bearing, seals, etc.

The crank was good enough to use without a regrind (not bad after 180K miles).

The heads were in pretty reasonable shape, no cracking! apart from the exhaust valves which where absolutely shafted!! Once the springs had been removed you could wiggle the valve in its guide nearly 5mm in all directions. 4 new exhaust valves and guides later should cure its oil drinking problem.

New stuff so far:
KB pistons
camshaft
4 valves
4 guides
followers
heavy duty oil pump
bearings, seals, etc
2 x DRLA Del's (need overhaulin') and manifolds with CB Performance linkage
CB Performance Breather

Still need:
Pump/Reg.
Clean tinware
Electronic Ignition
Exhaust, just header and muffler, plan to get hand built in stainless by Turbo Thomas here in the UK.

unfortunately I don't have any shots with the engine in pieces

http://img.photobucket.com/albums/v1...ey/engine1.jpg
old body board makes a good drag-able engine trolly

http://img.photobucket.com/albums/v1...ey/engine2.jpg
nice and clean, just ready to match port the manifolds

http://img.photobucket.com/albums/v1...ey/porting.jpg

http://img.photobucket.com/albums/v1...onkey/carb.jpg

Nice Job, Nige.

I got mine back together last spring, and also did some upgrades like 96mm KB pistons and a webcam. I was lucky enough to get a set of the LN Engineering Birals before they stopped making them. It made for a really pretty longblock. Anyway it's quite a thrill the first time you fire it up!

http://forums.pelicanparts.com/uploa...1105930004.jpg


I had a devil of a time keeping the mice from trying to store seeds in my engine, that's why I have the paper in the intake manifolds.

Nige,

Motor looks good - I have a nasty feeling I'll be needing a re-build myself soon! What dissy are you going to use? Is that a 009 that you've got set up on there or an 050 or are you doing something clever with the carbs to use the original?

On your old set-up you had the emissions stuff removed didn't you? If so where did the vacuum hoses from the dissy go to. I had previously assumed that they went to the two ports on the throttle body but I read something recently about one of them going to the EGR system (which I don't have) - I'm thinking I should block off the one that isn't the advance.

Ta,

Lee

Lee

The vac hoses go to the EGR and throttle body, if you haven't the EGR setup just put a straight hose from the dissy to the throttle body, thats what I did.

I'll be using the standard dist, 060 I think, the carbs are off an Alfa and have been converted and jetted to suit my engine. They have a vac advance port so I will be able to use the standard dist. I will be going Pertonix also.

Hope that helps, I have some photos of the engine in the car showing all the EGR stuff that's left over, you can see where the vac hose would go to.

http://img.photobucket.com/albums/v1...key/engine.jpg

Cheers Nige,

Both vacuum hoses go to the throttle body as you suggest. I don't have any part of the EGR left on mine.

Lee