Very few of these engine cases are reusable. VW often considered these cases
as consumable and factory rebuilds often had new cases. A recent water boxer
I installed even had a new case. Rebuilt heads but new case. You can keep
spending money thinking you are saving but until you really know what to
look for, you will do this many times.

My suggestion is to get a completely rebuilt long block with a warranty.
Since you can at least do the install, you can save some funds there. Try to
get a warranty that includes some labor compensation. Understand that most
of these rebuilds will have welded and re-machined parts. These engines in
general just do not have long life spans. Yes, some have gotten good service
out of them but they are prone to overheating and the stud pulling, case
twisting that comes with it.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Nathaniel Poole
Sent: Wednesday, October 18, 2006 7:43 PM
To: vanagon@GERRY.VANAGON.COM
Subject: <no subject>

SO I got the engine out and flywheel off (needs a new flywheel), heads and
cylinders off. Unfortunately Dennis was right about the block - the rear
thrust bearing is moving in its seat, I can rotate it about 1/8" inch.
Nobody in Vancouver area can machine these blocks and there isn't an
oversize bearing available, so it looks like a new used block for me. I'm
leaning towards letting the machine shop do the parts swap - polish the
crank, mic everything, install new bearings, probably new cam and lifters. I
could do this part myself and save $400 bucks but the chances of fouling up
something are good as I have NO experience with these engines. It's weird,
this engine was rebuilt not that long ago from all appearances - no cylinder
ridge and you can still see the crosshatch marks on the cylinder walls, oil
galleries drilled and plugged. I know the heads were rebuilt this summer.
Yet all told I'm still looking at a grand, not including new exhaust and
heqter boxes, and I'm still left with a questionable motor. So now I'm
wondering what one of these engine conversions cost?