Wap, wap, wap. Options

[DBCooper]

QUOTE (aircooledboy @ Jul 19 2005, 06:36 AM)

Engines, P/N 071 100 031AX, 039 100 031 B/C/DX, have been modified to improve heat transfer an increase durability. These changes effect Engine codes: GD, GE, CV. The following improvements have been introduced as of remanufactured Engine number 89000.

I think you're reading that wrong. It says that VW's own reman engines were changed as of that date. I'd say if VW found that change to improvge VW's engines being rebuilt to be put into VW cars and busses then it's probably equally effective on VW's engines being rebuilt to be put into Porsche cars.

As for lapping the cylinders I can say from experience that it pretty much eliminates sealing problems in VW engines in VW cars. If you look at machined aluminum under a microscope you'll see that there's no such thing as a "perfect" machined surface. There are always imperfections, high and low. Lapping doesn't remove any metal to speak of, little or none on the tops of the steel liners and not enough to change any angles in the mating surfaces, it just takes off the sharp tops of the ridges and microscopic galling in the aluminum. It's still not perfect, but it's a better mating surface than the raw machined surfaces.

[Cap'n Krusty]

QUOTE (r_towle @ Apr 25 2005, 03:15 PM)

if its head to cylinder, then you need to make sure those surfaces are lapped correctly prior to final assembly...otherwise it will happen again. the machining is very important that the cylinder to head and cylinder to case connections. These must be square and flat...then lapped. Good luck No gaskets if done correctly. Rich

If they're "square and flat", WHY would you EVER introduce potential deviation by lapping them in? WHY is this a "must"? If your machine shop were as good as the one I use, you wouldn't need to do ANYTHING to the heads except wipe 'em off before installation. And what is "lapped correctly"? The Cap'n, irritated that this myth never goes away!

[redshift]

Forgive them Cap'n, they are laplanders.

(IMG:http://www.914world.com/bbs2/html/emoticons/rolleyes.gif)

M

[aircooledboy]

QUOTE (Paul Illick @ Jul 19 2005, 10:46 AM)

I think you're reading that wrong.  It says that VW's own reman engines were changed as of that date.  I'd say if VW found that change to improvge VW's engines being rebuilt to be put into VW cars and busses then it's probably equally effective on VW's engines being rebuilt to be put into Porsche cars.

That is possible. I guess the question is whether they made changes to the engine and/or head to allow for the omission of the head gasket. If they reduced the compression in the reman engines, but the stock engines were not reduced, that is a pretty big deal.

In my line of work the assumption is that if an idea that could have easily been spelled out wasn't, then that idea was not intended to be conveyed. That SB doesn't say "leave the gasket out in all future engines if you take the heads off". I understand that the world doesn't always follow that logic, but if you are sending out SBs that are intended to educate your service departments. . .

I don't know the answer to this question. I am going to build a 2.0 soon though. I find it interesting though that this idea gets debated alot, and you often hear about an SB that says "leave the gasket out from now on" (and not just you DD), but every time an actual SB is cited or posted, it is this one, and it doesn't say that. (IMG:http://www.914world.com/bbs2/html/emoticons/confused24.gif)

[type11969]

I know that at least Jake and I'm pretty sure other t4 builders out there do not use the gaskets, they lap the heads to the cylinders, and they don't have longevity issues.

You can take what you want from that. I left the gaskets out of my 1.8, set the CR, lapped the heads, and haven't had any issues with leaking. And the CR is higher than stock. Just my experience.

[Bee Jay]

I didn't mean to start the gasket vs no gasket arguement again. All I know is that we used the gasket, and it failed. I don't plan on putting them in again. Now I will have gaskets on one side, and no gaskets on the other. I hope a gasket on the other side doesn't fail later.
The Cap'n has agreed to rescue my head. He also told me a neat trick to get my head off without removing the oil cooler. I guess Crusty has some 'sperience.
Bee Jay
PS I still hope to make Ventura in Sept.

[Kargeek]

Nice Car! I too like the starter button and I like the sub in the passenger foot well. I love to see innovation and quality craftsmanship! The sub looks like something I installed in my daughter's Ford Explorer- it is used in the rear storage area. DH

[DBCooper]

QUOTE (Cap'n Krusty @ Jul 19 2005, 08:18 AM)

If they're "square and flat", WHY would you EVER introduce potential deviation by lapping them in?

Yeah, I've been through this discussion before too. Your sentence started with an "if". And IF they were perfectly flat and square you're right, pure truth, you wouldn't need to. But check the next machined aluminum surface you get back from your machinist under a microscope. Tool used a bit too long, just a tad dull somewhere, running a bit fast, a bit slower, maybe got a bit hotter on the last head? If it's not this time it will be some time. And even if the tool is perfect aluminum isn't that mallable. Looking through a microscope I think you'll see that his "perfect" work is not really perfect, not absolutely flat. But five minutes of lapping makes the aluminum heads a mate for the (mass produced and almost certainly you can see it with your bare eyes not perfectly flat) steel cylinders. You're not introducing a deviation, they weren't perfect to begin with so you're mating the two. Look at them through the microscope again after they've been lapped, you'll see. And I lap valves, too!

And I'd also observe that if the engine manufacturer thinks enough of it to send out a service bulletin advising everyone to change their procedures it's probably because there's good reason. Manufacturer's don't much like admitting in public that they did a boo boo.

[Bee Jay]

I gave head to the Cap'n!!!. Now I know why they call him crusty :-).
Anyways, he boxed the head up to ship to EMS. It is repairable. If VW put out a bulletin about these head gaskets, there must have been a problem. This gasket let go with less than 2,000 miles on the rebuild. Now I'm a believer, no gasket. This was not in the budget. I'm gonna run out of time and money before the 9/11 meet in Ventura.
Bee Jay

[markb]

I dropped the head off at the UPS store this afternoon. It should get there tomorrow. The Cap'n was working on your trans when I left the shop. It would be nice if you had the car at GAF.

[Bee Jay]

Heads are back from EMS. Check them out.
http://www.picturetrail.com/gallery/view?p...2754&uid=598455
Bee Jay

[rhodyguy]

wow!! all new valve hardware? stock sized valves? i have to ask... if you don't mind, what did the bill run per head? no to include shipping. please pm me if the numbers are top secret.

k

[Allan]

Purdy.

[ArtechnikA]

QUOTE (Bee Jay @ Jul 20 2005, 01:05 AM)

I gave head to the Cap'n!!!.

that just doesn't sound right ...

[Bee Jay]

The Cap'n and EMS examined my head carefully and determined that my intake manifold gasket was leaking, running #4 lean, and prolly caused my head gasket failure. It's also prolly why the car started backfiring a while back. The only intake manifold gasket available for the 2.0 is this hard phenolic thing. Should I install it with gasket sealer or silicone? Do I peel the paper off on both sides, or leave it on? What torque setting should I use on the intake manifold bolts.
The Cap'n says to put the head sealing gasket back in. Since I trust him, it goes in.
Bee Jay

[Bee Jay]

Bump!
Hey guys, I gotta know. How do I seal this intake manifold gasket?
Bee Jay

[scruz914]

As far as I know you don't put any sealing compound on the manifold gaskets. Leave the paper on both sides of the plastic (phenoilc?). Torque should be around 14 lbs.

-Jeff

[Bee Jay]

I'm just about ready to lower this car, add oil, and start it. Head rebuilt, tranny rebuilt, new seats in.......
One last thing to do before lowering. My dumb butt took the oil temp plate out. I'm ready to put it back in, and the rubbler oil ring gasket is wayyyyyy to big. It has stretched. It's Saturday, a three day weekend. I wanted to start the car today. Where can I find this rubber gasket? Is it unique to Type IVs, or is it a common VW part. If so, I can catch NAPA before closing. If not, I guess I spend the rest of the weekend doing yardwork and honey do's. The Cap'n is not in, I called. Dang, the weather is perfect for Porsche test driving.
Bee Jay

[Allan]

I'd say take the cover and seal to NAPA and see if they can match it up...

[Cap'n Krusty]

QUOTE (Bee Jay @ Sep 3 2005, 01:46 PM)

I'm just about ready to lower this car, add oil, and start it. Head rebuilt, tranny rebuilt, new seats in....... One last thing to do before lowering. My dumb butt took the oil temp plate out. I'm ready to put it back in, and the rubbler oil ring gasket is wayyyyyy to big. It has stretched. It's Saturday, a three day weekend. I wanted to start the car today. Where can I find this rubber gasket? Is it unique to Type IVs, or is it a common VW part. If so, I can catch NAPA before closing. If not, I guess I spend the rest of the weekend doing yardwork and honey do's. The Cap'n is not in, I called. Dang, the weather is perfect for Porsche test driving. Bee Jay

Call me! Come and get it. In fact, come and get 2 or 3 of em! 925 1993
The Cap'n