2.0L Engine Rebuild (Yes another one), Engine rebuild thread Options

[Dtjaden]

I started this process a couple of months ago - in time for Dr. Evil's transmission rebuild clinic at McMark's but as a newbie and for other newbies I thought that I would document what I am doing. This may help out some newer World members but, for my benefit, hopefully some old timers can set me straight when I veer off track.

I started this because the 1.7L 914 I purchased in June had an engine that was down on power and leaked a SIGNIFICANT amount of oil. I also was not happy with the dual Weber IDF carbs so I plan to replace them with FI. A few months ago I found a 2.0L engine for sale a few miles from me so I picked that up to be the basis of the rebuild. That engine was not running and had not run for a few years. Depending on the condition of the crankshaft I will be building either a 2056 CC engine if the crank is good or a 2270 CC engine if the crank needs to be replaced.

My first step was to determine the problems with the engine. While the crank would move it would not turn through a full rotation. I removed all of the engine tins and then the heads. I found that the number 4 cylinder had dropped its valve seat. It was captive and had hammered into the head.



I had the heads cleaned and lightly bead blasted at a local engine builder. I emailed requests to a number of well known machine shops that specialize in 914/VW Type 4 head work (EMW, Brothers Machine, Headflow Masters and HAM). After a few days I have heard from two of those, Brothers and Headflow. Adrian at Headflow Masters has a very good reputation so I will most likely use them for the work. I plan new valves, seats, springs, the exhaust port repair and the repair of hairline cracks around 3 of the spark plug bores. The heads will also be lightly ported and polished.

Continuing with the tear-down today, I split the case Virtually everything in the engine will be replaced including the cam, pistons and cylinders, oil pump. I will use the existing connecting rods if they meet spec.







Tomorrow the case and other exterior parts will be off the be cleaned at the local machine shop.

[stugray]

I will replace the lifters with those from a1.7L engine so that I can use 911 swivel foot adjusters.

You mean "rockers" and since you have a "spare" 1.7, you can just use those.
You can remove them without disassembling the engine.

In fact, you can put the 2.0L rockers on the 1.7 to keep it "whole".

[Dtjaden]

I will replace the lifters with those from a1.7L engine so that I can use 911 swivel foot adjusters.

You mean "rockers" and since you have a "spare" 1.7, you can just use those.
You can remove them without disassembling the engine.

In fact, you can put the 2.0L rockers on the 1.7 to keep it "whole".

Yes, good catch, I absolutely meant rockers. That will teach me not or re-read what I write. Actually, I picked up a set of 1.7 rockers off of evil bay for a very reasonable amount to make life easier.

Although I mentioned I was planning to utilize fuel injection on the rebuilt engine to increase drive ability, part of the reason for that was to eliminate the whoosh from the carbs. WAF improvement. The 2.0l engine included all of the FI parts except the fuel pump. At a later time I plan a MegaSquirt conversion for the FI and ignition - just for fun.