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Engine Case Prep
Engine Stand
The engine stand was fabricated from 40mm box section. I built it so that in the long run I'll be able to run the engine on the bench.
Drilling and tapping the engine case plugs
Four plugs to be drilled and tapped on the back of the engine (front is front remember... :-)
...four plugs on the left side of the case...
... and three plugs behind the flywheel... EXCEPT... the late bus cases with the built in fuel pump boss. In which case only drill two of the plugs. In the image above plug on the lower left [right case half] should not be touched. The reason being, if the brass fuel pump guide is drilled through, you will have no oil pressure. If you did drill it like me, you will need to fix it. Pics to follow...
The plugs to be fitted are NPT (National Pipe Thread) tapered pipe plugs. I used Ally ones as I didn't know about the steel versions. Supposedly the steel ones are easier to remove at a later date whereas the ally ones get wedged and all but impossible to remove. The taps that I used needed to be cut down in order to get the plugs to fit in the correct place (tap sizes 1/8, 1/4, 3/8). Drill sizes for NPT (National Pipe Thread) in metric. Some of the original plugs wouldn't pull out and were destroyed in the process.
The following pics were taken from this thread on the ShopTalkForums and AREN'T mine. They are here purely for reference purposes as they show which plugs that need to be drilled and tapped. Here is the thread they were sourced from:
There's 11 plugs in total do to on a Type4 except on the bus cases when you only need to do 10:
The plug on the left, in the image above, should be left alone if you have bus case (i.e. built in fuel pump boss and guide).
Measuring Bearing Bores
Although it's a new case I decided to measure the bearing bores just out of interest using a depth gauge.
Deburring
Taking off any high points and burrs on the case halves with a stone.
Cleaning Case Halves
Case halves cleaned with an engine degreaser
Machined for a Porsche Fan
Cap for breather tower
Head studs
The threads in the case for the head studs need to a tap run through them for the ARP studs. Installation procedure can be found on the LN Engineering site.
Longer oil pump studs for 30mm Shadek pump and full flow cover.
Plugging oil pump outlet in the case for full flow (along with plugging oil pump outlet).
