1. The pistons may look fine but do they measure fine? Are the ring lands,
skirts, etc, etc still in tolerance? In my opinion, Mahle is best.

2. The cam & followers should be replaced as a set. Replace one & you should
replace the other.

3. Break-in is usually 500 miles - by then the rings should be worn to the
profile of the cylinder walls. I always change my oil & filter after 500
miles because break-in is really a short term very high wear period for the
engine and I want to get all of the micro-fine bits of metal out of the
engine.

Thanks,
Tom Hargrave
www.kegkits.com
http://www.kegkits.com/JABF/
256-656-1924

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@GERRY.VANAGON.COM] On Behalf Of
Robert Stewart
Sent: Tuesday, April 07, 2009 10:50 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Engine Rebuild Questions

I spoke with Pete from Van Cafe where I am ordering most of the parts
and he too suggested replacing the rod bolts thanks for the suggestion.

I a couple more questions...

1. Why is it important to replace the Pistons if they look fine? I
understand the rings and other components but why the actual piston?

What brand of pistons is best?
I see the several brands:
-  German made Mahle which are most expensive
- QSC from China
- Brazilian
- What are peoples experience with the 96MM Big Bore Kit from QSC?
Worth the extra horsepower or does it create to many problems with
heat in the engine and not a long lasting product?

2. If there is no visible wear on the camshaft does that still need to
be replaced?

3. What is the proper break in period after a rebuild?
I have heard that after driving the van for 500 miles I should change
the tranny fluid and oil?

Thanks,
Robert
Orange County NY

On Apr 7, 2009, at 3:02 PM, Jake de Villiers wrote:

> Replace the rod bolts with the uprated components - they are the
> weak point in the 2.1 motor.
>
> Pretty sure someone already brought this up in this thread...
>
> On Tue, Apr 7, 2009 at 11:32 AM, Robert Stewart <robertmstewart@mac.com
> > wrote:
> Just got back from a meeting the rebuilder and we are replacing:
>
> oil pressure valve
> oil pressure relief piston spring
> All New Lifters
> New AMC Spanish Heads
> Wrist Pin Bushings
> Cam Shaft - Reground from Van-Cafe
> Complete Gaskets Replacement of All seals
> Piston Cylinder Kit - From Van Cafe - German Mahle  ( does anyone
> recommend the 2.2 piston kit from Vanagain or GW?)
> Piston Engine Ring Set - Grant Brand
> Standard Main Bearing Set
> Crank Shaft bearing kit
> Rod Bearings - Standard
> New Temp Sensor with Lower threshold to keep the engine cooler* - Van
> Cafe 80 degree
> New Oil Pressure Sensors
>
>
> The rebuilder said all the other parts looked good.
>
> Indeed he has done these before he said and he realizes the
> complicated nature of how torque ratio's and well as the extreme
> precision of the tolerances are required. In fact he said he really
> dislikes working on all the German engines regardless if it is VW,
> Mercedes or BMW. For him hey says they use way to many bolts and misc.
> parts to complicate the process. He told me once the parts arrive he
> can have it done within 3-4 days. Sound about right?
>
> Am I missing any other crucial parts to replace?
>
> He said the crank, stud bolts and other key parts all looked good and
> said the engine seems in otherwise good shape for its age.
>
> Thanks for assistance.
>
> Rob
> NY
>
>
>
>
> On Apr 6, 2009, at 1:29 PM, Robert Stewart wrote:
>
> Good Monday to everyone,
>
> I have a local engine rebuilder working on my 2.1 Automatic engine
> which had roughly 250,000 miles on it.
>
> He informed my heads needed to be replaced. I could clearly see the
> space between the two valves having a indentation bridging them and
> the surface areas were very badly pitted.
>
> I planned on purchasing a set of rebuilt heads from Van-Cafe, anyone
> think this a good or bad idea?
> Anyone used them before? Have any feedback?
>
> Secondly is there anything regarding the rebuild that is a must to
> replace component wise since he has it all apart?
> i.e. sleeves, pistons, camshaft etc...
>
> I am awaiting a final parts list from him now but want to be sure I am
> not missing anything.
>
> Before he rebuilds it he is going to be cleaning all the parts in a
> special bath then glass bead blasting the non sensitive parts.
>
> Also how long should a standard rebuild take? i.e. 7-21 days? or is it
> something that can be done in a 40 hour work week?
> What kind of price should I expect?
> He told me it would be roughly $1500 dollars.
> He said he would be check to see if the camshaft needed to be reground
> and would check all valves etc. His shop only does rebuilds but of
> mostly race car engines and big truck engines so I trust he knows what
> he is talking about. He is not a VW guy at all he just knows engines.
> I did give him the Bentley just to be safe though.
>
> Any advice would be appreciated.
>
> Thanks,
>
> Robert
> NY
>
>
>
> --
> Jake
>
> 1984 Vanagon GL
> 1986 Westy Weekender "Dixie"
>
> Crescent Beach, BC
>
> www.crescentbeachguitar.com
> http://subyjake.googlepages.com/mydixiedarlin%27

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