So it started with an MOT.... in 2012

[1968911s]

Engine rebuild begins

[MarkIII]

Car looks great.

What are your plans for the engine rebuild, stock 2.0S build ?

[1968911s]

Hi Mark,

Plans are for stock rebuild, I initially bought 81mm barrels and woessner pistons, which also have a higher compression and are lighter than the mahles, this would have resulted in a 906 style engine, but have decided to stay stock.

The only difference to stock is that the new battles are all Alu rather than biral as the originals were.

(These were pretty scored up unfortunately where the old piston rings dissolved)

More pics to follow on the engine build. Rich

[1968911s]

Intermediate shaft loaded today.



Other half of the crank case sitting on the bench.

[1968911s]

Now two become one!

[1968911s]

All bolted up, recently powdercoated sump cover and tea strainer all bolted back in place, almost ready for barrels

[1968911s]

Pistons are loaded into the barrels to make for uncomplicated bolt up tomorrow

[1968911s]

Valves have been ground in and loaded into the heads

[MarkIII]

[quote="1968911s"]Hi Mark,

Plans are for stock rebuild, I initially bought 81mm barrels and woessner pistons, which also have a higher compression and are lighter than the mahles, this would have resulted in a 906 style engine, but have decided to stay stock.

Have to admit Stock 2.0S engines take some beating, if your a swb guy. I opted for 81mm barrels and wossner pistons.

[MarkIII]

Intermediate shaft loaded today.



Other half of the crank case sitting on the bench.

Your cases look pristine would be interested to know what process you used. My cases were aqua blasted

[1968911s]

Hi Mark,

I used the same cleaning process.

Rich

[Jimmy]

Rich

Did you check your valve spring compression, the replacement springs I bought (from the same supplier in Germany where our Mahle components came from) where out of spec so never fitted them.

Sorry - I sound like doctor doom. Hopefully your originals were fine.....


---------
Jimmy

[1968911s]

Bringing thread uptodate, springs are fine, and engine is now back in the car.

[1968911s]

[1968911s]

A journey that started with a failed MOT with the need for rotten torsion tube replacement, had the engine and rear suspension pulled out at my local specialist, and the body transported to a local metal worker... finding good metal to weld to was a challenge and one thing led to another... the job grew and time passed. Some years the stripped shell was resprayed back to the original grey, engine rebuilt, and the car drove for the first time... onto a transporter to be driven from Kent to Surrey