AE Engine – Preparation Thoughts

So with the new engine build almost ready to go in, it is time to start planning the removal of Żuczek’s AE engine for repair, clean-up, tuning, and installation into the 74.

This could go smoothly, or open a whole can of worms that I’m not prepared for.

That said, I’ve already been tinkering with it trying to get it run reliably, but I think there will be much more to consider once pulled.

Other than throwing on the plastic fresh air hoses, a new fuel pump, a new coil, and a new distributor, everything is pretty much like when I brought him home.

It appears that some of last night’s rain got in the decklid.

Once pulled from the car, there’s some obvious things that need to be done as well as some decisions made about how I want to put it in the 74.

Objective of AE Refresh

The objective of the AE Refresh is to get the engine cleaned up of grime and oil, get it running reliably with whatever carb options and distributors I have already purchased, and try to avoid creating any additional problems that require the input of money to solve.

Here’s what I’m thinking, based on the visible condition of the engine, as well as the sources of oil leaks and such.

Tentative Plan

1. Remove the stock pre-heater manifold (that’s been repainted already) and the stock dual ports replace the generic 34 Pict 3 carb with the EMPI single barrel dual EPC 34s I originally was going to to run on the 2019 AS41 New Build.
2. Remove the generator and replace with a basic internally regulated alternator (the generator pulley is probably going to have some issues being removed)
3. Remove all the tins and repaint them.
4. Replace the push rod tubes.
5. Remove the cylinders, clean, and reseal at the case (install the other set of pistons and cylinders I have if necessary).
6. Clean the heads up.
7. Fix the wiring on the harness as best I can for now.
8. Remove and keep the heat exchangers (if they are VW originals). Replace with J-tubes if they are original.
9. Replace the main seal.
10. If the cylinder tins are VW originals consider keeping them.

If I keep the stock carb setup, the boots will all need replacing. That oil cleaner can be cleaned up and repainted or I can just throw a basic air filter on with oil breather going to it.

If I remove the heat exchanges, the fresh air vents on the fan shroud need to be closed up.

Once in the 74

When it comes down to it, given the rust situation and shoddy previous owner repairs on the 74, I am not going to recoup anything on that car. This engine cleaned up and making the car run reliably will likely have more value than the car in and of itself. If I can get $2,000 for the 74 with it running I’ll be happy.  Making the engine sound is the best I can do since I cannot fix the rust issues.