Started into the bug again with favourable May weather. I cracked the case literally! But the contents have me perplexed.
Back during 'Phase 1' in 2020, I opted to pull apart the top end of the engine and do the top end rebuild only, seeing as I could get good end play which is an indicator of a good engine. But I found the #2 rod was sticky on the crank, not loose like the other 3, so I pulled a rod off a scrap shortblock and put it on. I couldn't do a proper check of clearances, as I was swapping them without removing the crank, and could only check tolerance by 'feel'. The longevity of the engine at this point, was 50-50 at best because of this compromise.
What was perceived as a 'knock' during startup developed around 3000 km of use, I say 'perceived' because when I pulled the engine apart fully this week, could find no evidence of loose parts that would cause any contact/knock. I pulled all the rods off the crank, and all the journals look beauty, like REALLY good. Even #2 only has some light scuffing, nothing that would catch a fingernail. weird.
I even checked all the journals against the wear limit of 2.1641" and they're all above that. Double weird. The case halves are even tight, and the mating faces are super clean, which makes me think that this is a VERY low mile engine as all the internals are VW stamped, even the bearings and the case has never been split! The cam bearings and lobes look mint. Triple weird.
So I went ahead and cleaned the AS41 case and inspected it. The thrust surfaces are also like new and still stock cut. It sure is nice to start with a clean slate. I could've easily reused the crank and rods, but CIP has a huge sale on right now with a cheap cast counterweighted crank and stock rods at half price. May as well replace it all. So far, we're $800 in on this round.
There is one big problem though, she sat for a very long time with water in the sump and the area around the sump screen plate is very corroded, and might need some JB weld. It almost makes the case scrap...
I also split the spare AS21 fuel injected case I had sitting around. While the exterior is not as corroded, the main bearing is super worn, and someone scratched the mating surfaces with sandpaper. Grrrrr! The sump is also riddled with blue RTV silicone. I might use the 26mm oil pump out of this one, as by the looks of the main bearings, might have a newer pump due to the obvious struggle to maintain oil pressure. This case definitely needs line bore/thrust cut before use. I might use it for a 74/90.5mm build, who knows.
At any rate, both the Bug and GLI will have to be able to move under their own power by the end of summer, no excuses, as we'll probably be moving to a smaller house in 2025. Sad, but has to be done...
BTW, say hi to the newest addition to the family, Heiser! A 1 year old rescue Shepsky. He's fitting right in! We had to put Deena down in January....so Heiser has big shoes to fill!
