Volkswagen Bus 2007cc Single Port Stroker Engine Failure - Tear Down and Inspection

Today's video we are tearing down a 2007cc single port aircooled vw engine that lost compression on one cylinder and had a knock sound coming from the engine.
We'll open up the engine and check it all out.
Thank you for watching.
Please like, comment, share and follow along!
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[@user-zd3zi6lk2x]

It's funny , as a vw engine builder , we do grumble about splitting engine cases . But I think it's more about the engine being gungie with road dirt and usually burnt engine oil . I shine when I assemble CLEAN case halves and new parts on a clean bench and clean tools ! ! I also like to make the little 4 banger a little screamer . And that's why I do it . 👍

[@robertosantinni9656]

You were very sure to NOT point fingers at the builder. Kudos to you sir.

[@VWJawbreaker]

I don’t know him personally and not to mention this is most likely a part failure, not a builder issue. It’s the right thing to do.

[@kc9bpo]

love that proper foot attire for working on an engine.

[@DuckmanCycles]

You answered the question I always had.... AFTERNOON SUN! Ugh! LoL! I kinda figured it came in there pretty bad. For me in the morning sun in the driveway!

[@VWJawbreaker]

The time you stopped by, the afternoon sun about killed us in the garage. That’s why I mostly work in the mornings.

[@benkanobe7500]

I'm a Pilot and have been for over 30 years and been flying my own plane for 28 of those years. It makes me nuts when other pilots will judge a plane crash. If you were not in the cockpit, you don't know what the pilot was dealing with. Speculation is just that. Class Act of you to not judge the Builder. It could have been so many things that broke the first link in the chain of events that lead to the failure.

[@VWJawbreaker]

Thank you, I’m glad you understand. It’s not my place to point fingers but to help a friend get back on the road. No need to play the blame game, all that does is ruin people’s reputations and cause drama for no reason.

[@wickedwerks]

Glad I’m not the only one getting trash rod bearings 😂

[@VWJawbreaker]

Completely trashed that new crank and that one rod.

[@michaellicitra7632]

The excessive discoloration on the rod and bearing with all other surfaces sparkling clean and no discoloration especially with just 500 miles on the engine tells me the problem started immediately when rebuilt. It looks like no oil to that connecting rod bearing and since it looks like it started from time = 0 it most likely has to do with no oil from a bearing oil hole misalignment or even an improperly drilled crankshaft oil hole. Good Video.

[@VWJawbreaker]

I’m thinking the same, this most likely started from the beginning. I didn’t mess with this crank that much but from what I did check, all oiling holes were lined up. I have a few theories however that won’t be posted due to protecting the builder’s reputation.

[@vwdarrin]

It happens to everybody. Too many RPMs for an extended time. To reduce the chance of this happening again if you buy a crankshaft for this Motor be sure to buy a Chevy journal the smaller diameter slows the bearing speed down which lets the bearing live longer at high RPMs. Buses are very hard on parts. Biggest oil pump you can fit in it in the biggest cooler you can put underneath the bus lol

[@VWJawbreaker]

Man I wish I would have talked to you about this back when I was working on it a few months back. Ended up going with a VW crank but new cb rods.

[@vintage76vipergreenBeetle]

Great information, Darrin.

[@67VWForever]

Nice info, Vwdarin. I will screenshot that..thanks.

[@torbenalstrup3902]

The bearing surface speed has nothing to do with that problem, and especially not with the rpms such an engine will do. It is an oil pressure or oil supply issue, - or, too tight bearing clearances from the beginning. Also, opinions vary, but I would never build an engine like that w.o. extra oil capacity. The 0,3-0,4 liter extra from a simple filterpump does wonders in securing oil supply at almost all times. Another thing. Jawbreaker is almost too polite towards the original builder. I mean, 0,090" deck!!!! JEEBUZZ! I thought we were passt that. Apparently not.

[@martinharris5017]

This is a win-win both for your friend with the busted engine and for all your other friends watching and learning. I'm especially interested in this one being a single port w100 cam engine owner/builder. Thanks for letting us watch along as you diagnose, Gary! Edit: really civil of you not to bash the builder too. From what Ican see on the vid it was a pristine and honest build and I agree, it's "just one of those things" happens to any old engine.

[@VWJawbreaker]

It really is a win win for the birth of us. He’s out approximately the same either way, possibly cheaper with me doing the work and faster turn around time. Plus we all get to learn a few things along the way.

[@Mikefngarage]

also check the crankshaft plugs to make sure one did not come out. need to have red loc tight on the threads.

[@VWJawbreaker]

They were all tight as well.

[@TheEZGZ]

Thats a great engine choice for a bus but you just can't run the bejesus out of them. Deep sump would help and elephant ears to get more air are always a plus. Thanks for not killing the builder. Your getting more experience by having a look. I noticed it was a older case. I wonder what crank and rod specs were.. Gary, your the best. Thanks for being you!

[@VWJawbreaker]

It’s a great torque engine for sure. Another guy is running the same engine from the same builder, one in his single cab and the other in his bug. Both run amazing. It was easier and cheaper for me to do the work and all I want is to see his bus back on the road. From what I can tell, it was a new crank and resized stock VW rods. Next video we’re doing the prep work to get the short block put back together with new cb crank and cb rods. Thank you for being you!!

[@MikeMoose67]

Great camera work. Super cool of you to do that for a friend at no charge for labor. That is awesome. Great video.

[@VWJawbreaker]

Thanks buddy. Just trying to spread good karma.

[@royworks28]

You’re a smart man Gary. It’s great to see knowledgeable mechanic.

[@VWJawbreaker]

Thank you sir but there are plenty of people that are way smarter than I am. I know enough to get by and try to spread what little I know.

[@bajarunner1128]

Sharing an inside tip here most never realize. While things like bearing clearance and quality can certainly be a problem, The failure is typically in the choice of the center main bearings design and the fact that this crank has straight drilled oil galleys. Parts match up if you will. The center main has to feed oil to both the #1 and #4 rod journals, it has to move a lot of oil! Straight drilled cranks need a 360° groove in the center main like the factory Kolbenschmidt bearing used in the early Straight drilled crank VW engines. This keeps 1 and 4 well oiled at all times. Cross drilled cranks can use a non grooved bearing as they have the tear drop in the crank to pick up the oil as used in the later VW engines. But a non grooved bearing coupled with a Straight drilled crank is asking for trouble! Sure plenty have been built this way, but it isn't correct.

[@VWJawbreaker]

Very true, thanks for sharing!

[@VWLifeVW]

I dig the stock weight flywheel on the stroker Bus motor. I always like weight to keep inertia going and launch the heavy vehicle - easier on the motor. I'd look into that oil galley from the #1 main to the rod. seems it may have stopped allowing oil to the bearing - SHRUG... Great work Gary! Tommie

[@VWJawbreaker]

I agree with ya there sir. I kinda wish I had a stock weight one for the Sickxty since it has the larger tires and such. I took a look at a lot of things, my opinions and what I may or may not have found are being kept confidential. Appreciate ya as always good sir!

[@Mikefngarage]

Sometimes the oil pumps slip on the shaft. and that is on shadduk pumps. We weld them to the shaft. Yea you should not have to but have seen several that do this. Check the oil pump put the cam portion in a vice and see if the gear spins. probably lost oil pressure then the rod came loose.

[@VWJawbreaker]

That’s a good point. I did check the driven gear and shaft, they were right with no slippage.

[@DesertRatFabrication]

Hey Gary cool video, to bad it had to fail, but hopefully it can be put back together, it’s always fun watching a motor get torn down, be looking to newer videos to see what happens, hope everything is well with you my friend 😀😀

[@VWJawbreaker]

Hey man, hope you and yours had a great holiday season!

[@jeffcoleman5160]

Great video Gary.Thanks for being you.Hope to meet up with you some time.Long drive from KY

[@VWJawbreaker]

Yeah that’s definitely a drive. I do appreciate you greatly sir.

[@Thomas-fo9zu]

Its such a pleasure watching you tear down a v-dub motor. Youre a good guy not to tear up the tech that did the work, like you said, parts fail. I did a clutch on an old pick up with a 3 on the tree and it would not go into gear.The diaphragm clutch was shit brand new. I had to do it over with different parts and at first got blamed for doing it wrong. I suggested a 3 finger disc and it worked perfectly.

[@VWJawbreaker]

You’re right, sometimes we do get bad new parts. Sometimes parts fail for whatever reason that’s out of our control even though everything showed to be within spec. Thanks for being here, I appreciate it.

[@DuckmanCycles]

My SV650 puked out a big end rod bearing out the sides of the rod, one of the pistons would bang on the head it was so loose.. I replaced the bearings, and it ran great for a few minutes, then it slowly started doing it again. I think there was a problem with one of the oil passageways, but didn't care. It was waaaaaay too much work on that engine for me to want to take it apart again. LoL! Rather split a VW engine any day!

[@DuckmanCycles]

Yep, the bearing puked out the sides of the rod lol, sure looks familiar haha

[@VWJawbreaker]

Oh man, that sucks. Those SV’s are a beast!

[@tomschmitt5723]

I can't tell you how many newer Volkswagens I've worked on for free . That's what it's all about best thing about owning a vw the community....good for you...

[@VWJawbreaker]

It’s all about taking care of one another and putting out good karma. I wouldn’t feel right charging someone for my work, I’m not perfect either. We all make mistakes, all o can do is the best I can.

[@dubworldvwadventures]

My back hurts watching you working barefoot on concrete!

[@VWJawbreaker]

I’m more comfortable that way.

[@dubworldvwadventures]

@@VWJawbreakermore power too you my friend! I’d be paying a big price of back pain! But the other reason I wear shoes is the tendency to bang into stuff. 😅

[@RollingThunder808]

Oil pressure or flow problem caused the con rod bearing to fail. That needs to be fixed.

[@VWJawbreaker]

Most likely an issue. I did find the culprit but haven’t said anything as I don’t like to bad mouth people.

[@douglasbarnhart3324]

Thanks for the video.

[@VWJawbreaker]

Thank you sir.

[@deanrobinson3717]

Great video and break down Gary, as you know, it is a bit close to home that one, my fault on my one though, but that sucks and obviously a duff part, great shout out to the builder too. Love to the family pal

[@VWJawbreaker]

It does suck but all we can do, like you did, is move forward and make things right to get him back on the road. Keep feeling better my brother, tell everyone we said hey!

[@vdub6873]

Great intresting video love it

[@VWJawbreaker]

Glad you enjoyed it

[@rixward5475]

loooks like the oil control rings were not gapped , so they butted , scored the bore & broke , so metal bits went thru the oiling system before the oil filter , blocked oil gallery in the crank. 1 simple error causes so much damage

[@VWJawbreaker]

That’s a very good possibility.

[@gregmurray8883]

Love your mates rates work. Very inspiring!

[@VWJawbreaker]

Thanks so much!

[@kevinhamling1963]

G'day Gary, Great engine inspection. ✌️ Peace

[@VWJawbreaker]

Thank you buddy.

[@Mikefngarage]

OK Here is what I think happened. this sucker ran lean. and got the oil too hot and caused it to break the rings. I dont think this was an oil pressure issue. Lean semi dry seized and wiped out the bearing. Here Is what I would look for Main Jet should be 140 or 135. also the rods are stock. Which I never do on a single port 2007. I use the 5.325 short rods I beam. so you dont need such thick shims. the intake manifold probably was not properly seated on the heads. because with those shims in there it was like 1/4 inch wider than stock. It may not look like it got hot but the Rings breaking on number 4 tell me something happened unrelated to oil. Check with Dario at AA. see if he can give you a new crank and short rod set. bearings and pistons rerun the rest. Try and get my account pricing and tell him your building it on youtube. 4140 should be fine. I didnt build this and dont know who did but like you say i am not sure they did anything wrong. but if I installed a single port manifold on there I would have widened it and tig welded the it. also checked for vacuum leaks. Doesnt take much on a bus to wipe out an engine.

[@VWJawbreaker]

Thanks Mike. This was purchased as a complete engine. All tins, intake and carb from the builder. He ran them before shipping them out. The other engines from the same builder haven’t had a single issue and have been running great for a long while. I appreciate the offer but this video is way behind, by a few months. The engine is already back together and in his bus. Definitely appreciate your thoughts on this and taking the time to watch and comment. I’m pretty sure I know what happened however I won’t be discussing the details due to protecting the builder.

[@Slick56]

Such a bummer eding to what is ideal combo that should be perfect for a bus, but things happen. Excellent of you to do the autopsy. Number 3 is often starving for oil at the best of times but once the bearing loses the fight knocks and heat are next. Good work let us know what happens.

[@VWJawbreaker]

It is unfortunate however things do happen. All I can do is come up with a game plan and get him back together. Next weeks video we’re putting him back together once again. Anything I find or my own opinions are being kept confidential, I don’t want to ruin anyone’s credibility. This was not a builder issue.

[@yoshinoyajones8924]

Hey, Brother from another coast!! as always dig the vids. Unless he built it in a vacuum, even the pros have fails. I was hopin for a good result, as my own 70' bay winder needs more hps. Good luck.

[@VWJawbreaker]

Hey man! This is a solid combo and well worth the time to put back together. There’s 3 other exact combo engines from the same builder running around without problems. Great running engines and these are setup for single carbs. No clue on the jetting though.

[@ChipsAndSparksGarage]

Makes you wonder how the bearing material snuck itself out from between the crank and rod. Looks like the block is still good, though.👍

[@VWJawbreaker]

Has to be an issue with the rod, maybe out of round or something. Everything else besides the crank and rods is In perfect shape and will be reused.

[@V8N8T]

Damn ive never seen a bearing do that!

[@VWJawbreaker]

Pretty sure that’s what caused the loss of oil pressure 😂

[@V8N8T]

@VWJawbreaker I'd say so! Excellent splash oiling though 🤣

[@VWJawbreaker]

@@V8N8T 😂😂

[@vintage76vipergreenBeetle]

There is reason why vw put type 4 engines in bay windows buses. It still wasn't good enough to last.

[@VWJawbreaker]

True but it’s an early bay and he wants to keep it a t1 engine since the trans is geared for that.

[@wickedwerks]

Hey thanks 😂

[@VWJawbreaker]

No problem! 😎

[@magaisacult2023]

Amanda and I are looking fwd to seeing you and the baja at Bug Jam!

[@VWJawbreaker]

Yes sir, we will be there with bells on!

[@briancole7935]

So you did get to work on a bus! 😆😆 (Please don't delete me!)

[@VWJawbreaker]

Haha! I wouldn’t delete ya 😎🤙

[@stephenport4768]

Was that a quality issue with the big ends with the build on the previous videos id definitely have twin port heads as an upgrade

[@VWJawbreaker]

As far as I could tell this wasn’t a rod issue. The owner didn’t want to upgrade to dual port, single ports are good for busses.

[@douglasberry7004]

Why haven’t you put a mini split in your garage? You spend a lot of time in your garage working on the bugs.

[@VWJawbreaker]

That I do but I just can’t justify the cost.

[@2GuysandaBug]

Everything can be fixed. Sucks to have that happen though.

[@VWJawbreaker]

Absolutely. We’ll get it sorted out and back on the road.

[@Pnw-nick]

Curious how you got an equal deck height measurement with the bad rod bearing?

[@VWJawbreaker]

I wasn’t sure either…

[@thestove2407]

Not to assign blame, but documentation of the chain of failure is still being a true diagnostic assessment. From my arm-chair ... it looks like two distinct failures. 1) oil scraper ring failures 2) con/crank bearing failure. Are they related ? Thats is where experience comes into the equation. From my arm-chair: Oil ring overlap= gooved barrel. Grooved barrel = second ring comprised. Culminated ring failure friction = overloaded crank bearing. Crank bearing overloaded = blue con rod. Was there an oiling issue ? I'd suggest ... no. As the rings and crank are oiled from more than one supply, such as direct pump pressure oiling, and internal mist oiling. A) The crank bearing ... if un-oiled would affect the crank, but not affect the rings. B) If the oil ring failed ... it would, with significant certainty .. affect the crank bearing. Bubba = builder's name. Imho At 500 miles .. we could actual count the number of times the piston has stroked the barrel. The only component that is thin enough, to malfunction and not be easily detected = oil ring's thin corrugated spacer. It would take very little time to become sharp. Then become an extremely serious wedge, and get into the second compression ring. Then bind the entire piston with a great deal of friction, and that overloaded the crank bearing. The wedged piston's friction would never diminish ... and the crank bearing would just be mathematically overloaded. While possibly ... not builder related ... I'd suggest this was highly probably builder related. 😢

[@VWJawbreaker]

I absolutely agree with your statement especially about the oil ring. Seeing that the compression rings were not gapped at the spec I would have liked to see, that is what I believe took out the oil ring. Regarding the con rod bearing, I believe there was more to it than just what you mentioned. However, my theory and my additional findings I will not discuss because I do not bad mouth people especially in a public forum or video. If I have something to say to someone I say it to them directly.

[@moustachemike7128]

did ya rebuild or replace the crank .or turn #1 down to a smaller rod bearing size..

[@VWJawbreaker]

That’ll be covered in next weeks video.

[@VWRICH23]

#1 OUCHHH

[@VWJawbreaker]

Pretty much, we’ll get it fixed up for him.

[@VWRICH23]

BETTER THAN NEW@@VWJawbreaker

[@jimmywilkinson9190]

Hey Gary ! in 500 miles if that knocked sooo baaad #1 it didn't get oil #2 bad rod resize or they used a used rod that was sprung #3 owner shot to many rpm Gary are those OEM rods

[@VWJawbreaker]

He didn’t have an issue until that day other than it seemed the oil pressure was lower than I would have liked. These were stock VW rods, we’ll get him fixed up and back on the road.

[@SanDiego_VDubLife]

Do you what brand bearings and rings he used? I’ll make sure to avoid that brand 😆

[@VWJawbreaker]

No clue, I didn’t speak with the original builder.

[@craig162]

Good video. I'm a retired mechanic (33 years ) I have told customers Bad Luck many times when they would ask why something would go bad. Was it a bad piston or did something cause it ? Did it run lean or pre-ignition or a double case of bad luck ? After thought it was an oil ring, bad luck.

[@VWJawbreaker]

You’re right, sometimes things just happen. I have a few theories on what caused it but again, they are theories. I won’t speak of them due to protecting the builder’s reputation. As hard as it is for some to grasp, parts fail and sometimes there’s nothing that could have prevented it.

[@davemurton736]

Really enjoyed that video, great learning experience

[@VWJawbreaker]

Glad you enjoyed it!

[@vayabroder729]

Ouch! Doesn’t sound good. 2007 cc is a GREAT combo!

[@VWJawbreaker]

Yes it sucks but we’ll get it back together for him.

[@benkanobe7500]

Did the oil look all sparkly?

[@VWJawbreaker]

Oh absolutely!!

[@DuckmanCycles]

When can I pick up my motor? 😁😁😁😁😁😁😁

[@DuckmanCycles]

Oooh... it is noisy.... you can keep it lol

[@VWJawbreaker]

Someone came by yesterday and picked it up for you, they said you sent them. I already sent you the bill.

[@campervanbug7658]

That musta been a tourq monster, low rpm

[@VWJawbreaker]

It really is!

[@campervanbug7658]

@@VWJawbreaker was it just junk bearings?

[@VWJawbreaker]

@@campervanbug7658 there could have been 2 different issues that caused this but nothing concrete. What I suspect won’t be shared to protect the builder.

[@campervanbug7658]

@@VWJawbreaker yeplike the presents the last mechanic left me with🤣

[@type4revolutionstudio]

Piss poor engine builder ... definitely no fault of customer... make sure it has hd springs for a bus build

[@VWJawbreaker]

I won’t confirm or deny your comment but definitely not the customers fault. Springs are hd even though it’s a w100 cam. Can’t be too careful in certain situations.

[@type4revolutionstudio]

@@VWJawbreaker oil ring probably broken at install with that little bit of mileage . I've seen enough other builders to almost guess the origin

[@gravedigger8]

what kind of hp does that have?

[@VWJawbreaker]

Not sure, I don’t have a dyno.

[@gravedigger8]

@@VWJawbreaker got a guesstiment, 120hp +or-

[@VWJawbreaker]

@@gravedigger8 if I had to guess, being a single port will reduce max hp numbers… I’d say around 100-110hp

[@gravedigger8]

@@VWJawbreaker my wifes 67 has a stock 1200 or 1300 in it

[@VWJawbreaker]

@@gravedigger8 nothing wrong with stock.

[@robertosantinni9656]

The problem is quite obvious to me. It ain’t workin! 🤣 Sorry, I just had to be a turd.

[@VWJawbreaker]

It ain’t got no gas in it! 😂

[@DuckmanCycles]

China parts! Hehehe! Blame Canada!

[@VWJawbreaker]

Hard to say anymore. Most parts come from the same place.

[@thestove2407]

Hey ! ... Sorry ... it wasn't us ! 😅

[@moustachemike7128]

hows that yes welder working out so far..? i just picked up the ac/dc tig 250 can't wait to get it running.. i like bugs.. its easy to change out bodies ,,thks for sharing great content for owners...🪙

[@VWJawbreaker]

The welders been working pretty good over the last few years.