So as with any classic automotive project, you can plan everything out months in advance, but as disassembly occurs, you need to be able to move with the flow, and if necessary deal with situations that may change, especially as you discover problems and the like.
For my 2020 Murbella Projects, the suspension and brake plans have not changed and are exactly as I planned out last year. The same can be said of the transaxle repair plans so for.
However, with the engine out, and the discovery of far different oil leaks than originally expected, there were major changes in the scope of the engine that had to happen, or else it would likely come back to haunt me for not doing them now, with the engine dropped.
Engine Plan Changes
I had no intention of opening the case. The plan was for some internal cam inspection, but it was about new pistons and cylinders, new seals and such, and general case/engine clean up.
That all changed with the realization that the oil leaks were not coming from the main seal at all, and that the case halves needed to really be resealed anew. Cracking the case seemed the best way to do that and of course, seeing some wear damage on the camshaft and severe oil gallery and passages being partially clogged basically made me commit to a clean rebuild.
It was at this time I decided to make some non-stock internal changes when building it all back up. Most of these changes came about via conversations with engine builders, as well as an opportunity to take advantage of a few online vendor sales for Memorial Day.
Engine Internals
| Location | Part | Status | New Part | Reason |
|---|---|---|---|---|
| Short Block | Crankshaft | Upgrade | 4140 Forged Counterweighted Crankshaft VW Journal | To help balance engine |
| Short Block | Crankshaft Gears | Replacement | Type 1 crankshaft timing gear set | Some wear on cam gear and distributor gear |
| Short Block | Connecting Rods | Upgrade | Forged Chromoly I Beam Connecting Rod Set VW Journal | Easier to replace than find someone who can rebush |
| Short Block | Cam Bearings | Upgrade | Silverline Double Thrust Bearings | |
| Short Block | Camshaft | Upgrade | CB Performance Eagle Cheater Cam | Will work with existing heads and FI |
| Short Block | Camshaft Gear | Upgrade | VW Type 1 Aluminum Cam Gear | Needed for new cam |
| Short Block | Lifters | Upgrade | AA 28mm Lightweight Lifter Set "With Oil Holes" | To lighten valvetrain slightly, may not use |
| Long Block | Head Studs | Replacement | Chromoly Head Stud Kit | Originals could have been used. Some thread wear though. |
| Long Block | Intake Valves | Replacement | 33mm Intake Valves | Originals worn |
| Long Block | Exhaust Valves | Replacement | 30mm Exhaust Valve (9mm stem) | Originals extremely worn due to running hot |
| Long Block | Springs and Keepers | Replacement | Stock Springs and Valve Keepers | For head rebuilds |
| Long Block | Rocker Arms | Replacement | Rebuilt Stock 1500/1600 Rocker Arms | Temporary, may HVMX mod in the future and put originals back on after cleaning |
| Long Block | Rocker Arm Shafts | Upgrade | Solid Rocker Shafts | I prefer working with this style over original |
| Long Block | Flywheel | Upgrade | VW Cast Lightweight Flywheel 12V 200mm | Lighten drivetrain a bit, match crank dowels |
| Long Block | Pushrod Tubes | Upgrade | Stainless Steel Pushrod Tubes | I've had them for years for this build |
| Long Block | Crank Pulley | Upgrade | Stock Design Black Aluminum with Timing Marks | Match alt pulley, I like degree marks on pulleys |
| Top End | Alternator | Upgrade | 90amp Compu-Fire Alternator | More electrical delivery for stereo and lights |
| Top End | Thermostat Flaps System | Replacement | Complete restored flaps and thermostat | Replace what someone removed |
| Top End | Alternator Pulley | Upgrade | Alternator Pulley With Cooling Fins | Mexican Beetle style cooling fan for higher amp alternator |
| Top End | Distributor | Replacement | Restored Bosch 205H DVDA | Install correct distributor for engine |
| Top End | Throttle Position Sensor | Replacement | Throttle Position Sensor | Replace cracked plastic case |
| Other | Cylinder Deflector Tins | Replacement | 8mm Deflectors | Replace damaged |
| Other | Hoover Bit Tin | Replacement | Hoover Bit | Replace missing part |
| Other | EGR Filter | Replacement | EGR Filter | Replace missing part |
| Other | EGR Filter to Exhaust | Replacement | Filter to Exhaust Pipe | Replace missing part |
| Other | Oil Pump | Upgrade | Maxi Pump 3 - Full Flow In & Out (up to '70) | Looking at adding full oil filtration if possible |
| Other | External Oil Filtration | Upgrade | Filter, mounts, other hardware | Looking at adding full oil filtration if possible |
The decision to possibly add bolt-on only full oil filtration will happen during engine mock up stages based on how and where I could mount and external oil filter as well as routing the plumbing. I have not tapped the case for return, and all will be done via the CB Maxi Pump.
As with everything on Murbella, her original parts, including engine internals, will be kept and stored away in case there is every a desire to take her back to complete stock.