1978 2.0L GE FI Engine Refresh

Manfred · Post by **Manfred** » Sat Nov 07, 2009 2:33 pm

Hey everyone,

It's been a while since I've really contributed to the site other than just being a smart ass. So I'm starting this thread to document one of my winter projects.

I've had the bus since February of 09. I was able to get it road worthy by the summer and did some camping. I put about 3k miles on it it so far. The engine runs strong, but it needs to be gone through. The goal is look for any signs of things going bad and replace them before they do go bad and have her running like a champ.

The plan is to:

1. Remove the engine. Check. this I completed today. Pictures will be coming soon.

2. Thoroughly clean said engine.

3. Paint the tins

4. Test all sensors

5. Replace all fuel lines

6. Replace all vacuum lines

7. Leak down test

8. Pressure test

9. Clean and reset fuel injectors

10. Install new exhaust.

If there is anything you think I have missed, let me know and I'll ad it to the list.

sgkent · Post by **sgkent** » Sat Nov 07, 2009 5:00 pm

while the engine is out and the tin off you might consider replaceing the pushrod tube o-rings, pulling each lifter one at a time and inspecting the cam lobes for wear. After replaceing the o-rings, retorque the heads. Do not mix up the lifters.

Ritter · Post by **Ritter** » Sat Nov 07, 2009 5:02 pm

Replace all of the seals you can while it's out.

bajaman72 · Post by **bajaman72** » Sun Nov 08, 2009 10:26 am

Hey, that kinda looks like my list.

Manfred · Post by **Manfred** » Mon Nov 09, 2009 8:19 am

bajaman72 wrote: Hey, that kinda looks like my list.

I thought you would be done by now. :)

Manfred · Post by **Manfred** » Mon Nov 09, 2009 8:40 am

Engine pics:

Ok this is proof, I have removed my engine. Notice how the engine is out of the bus.

Engine Code GE=1979 with Vanagon Heads according to Ratwell. Are the Vanagon heads any good?

I believe it's 2382061166. 2=Type 2 3=Campmobile 8=78

Another view

6 rib tranny

dtrumbo · Post by **dtrumbo** » Mon Nov 09, 2009 12:07 pm

Manfred wrote: Engine Code GE=1979 with Vanagon Heads according to Ratwell.

Actually '78 buses came with GE coded engines.

Manfred wrote:I believe it's 2382061166. 2=Type 2 3=Campmobile 8=78

I believe the '3' denotes 'Kombi' which most campers were built upon.

Nice work! Now it's time to clean, clean, clean! It's miserable work, but it sure is rewarding when it's done. I'm currently going through this with Beetle.

Manfred · Post by **Manfred** » Mon Nov 09, 2009 1:03 pm

dtrumbo wrote:
Nice work! Now it's time to clean, clean, clean! It's miserable work, but it sure is rewarding when it's done. I'm currently going through this with Beetle.

Thanks! Cleaning is my project this winter. She is a dirty mess, no doubt about it. Should be fun.

Manfred · Post by **Manfred** » Mon Apr 05, 2010 7:53 am

Hello All,

I know I haven't been on for a while. But I haven't worked on the bus in a while either. The Chicago cold kept me out of the garage all winter, but not off line. I've ordered a ton of stuff for the engine. She's getting all new vacuum and fuel hoses, a thermostat (finally), cleaned and tested fuel injectors, new header, new exhaust, new clutch (I'm still on fence on putting a new one in).

This weekend we had great weather, so I decided to jump back into to my project. I was able to mount the engine on my new engine stand and remove the heater boxes, fan shroud, and tins. I also started cleaning the block and transmission.

Next steps painting tins, fan shroud, pulley, intake, etc.. having th starter rebuilt, installing all my new bits and bobs...

Fan shroud and Heater boxes still on. Will it hold? Notice my buddy's El Carte Salsa bike I built for him in the background.

Heater boxes and Fan shroud removes. Wow this engine stand did well, I was able to really work on the engine without fear of it falling on me.

chitwnvw · Post by **chitwnvw** » Mon Apr 05, 2010 8:39 am

Looks pretty clean.

You be ready to camp in a week or two?

Manfred · Post by **Manfred** » Mon Apr 05, 2010 9:21 am

Doubtful. My on the road date is May 1. I'm having the bus undercoated and the engine bay painted. I'm having a shop give me a quote and if I don't like that price, I'm going to do it myself.

But May 1 is the date. Keep your fingers crossed.

chitwnvw · Post by **chitwnvw** » Mon Apr 05, 2010 9:29 am

Undercoated? I'd be careful. How would they get it up on top of the frame rails and all the nooks and crannies. And if you don't get it all rust will creep under and you won't see it until too late. You might be just as well off spraying it with Waxoil once or twice a year. Just my 2 cents worth.

Manfred · Post by **Manfred** » Mon Apr 05, 2010 9:55 am

Well the people I rent my garage from don't want me painting in the garage.

Where do I get Waxoil? This isn't going to be a show bus, but I want to stop/slow the rusting process. I probably be driving it during the winter also.

chitwnvw · Post by **chitwnvw** » Mon Apr 05, 2010 10:09 am

This is about the same: http://www.gemplers.com/product/G55625/ ... nter-1-gal

http://www.gemplers.com/docs/IS/FLUID%2 ... 0SPECS.pdf

You just brush it on. I also try and get some in the internal cavities.

How much is undercoating?

Manfred · Post by **Manfred** » Mon Apr 05, 2010 11:23 am

chitwnvw wrote:This is about the same: http://www.gemplers.com/product/G55625/ ... nter-1-gal

http://www.gemplers.com/docs/IS/FLUID%2 ... 0SPECS.pdf

You just brush it on. I also try and get some in the internal cavities.

How much is undercoating?

I'm using KBS sealer. http://www.kbs-coatings.com/Rust-Sealer_c_2.html

I just called the guy for the quote and he still hasn't got it. I'm getting a bad vibe from this place. I smell DYI. I'm ordering the Waxoil today. Is there any place that sells it locally?

Itinerant Air-Cooled

Itinerant Air-Cooled

1978 2.0L GE FI Engine Refresh

1978 2.0L GE FI Engine Refresh