WBX

Big lumps of metals and spanners. Including servicing and fluids.

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what2do
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Re: WBX

Post by what2do »

itchyfeet wrote:you are right, the old covers are tired and rusty.
I was going to make some from sheet aluminium, if I don't get around to it I will get these...

My thinking is covers are there to protect delicate push rod tubes, not so important if they are replaceable.

Also scat tubes are rumoured to leak a bit so I want to monotor them, supplied seals are pants buy the small elring seals x16

https://www.brickwerks.co.uk/t3-parts/t ... overs.html" onclick="window.open(this.href);return false;

I still need to fit and test the speedi sleeve, will keep you posted :ok


One of the first things you recommended I do to my van when I first bought it was to fit some covers, at least one of my push rod covers has a substantial ding in it.
Why would the glass be anything other than half full?

'89 panel van, 1.9 DG.

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itchyfeet
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Re: WBX

Post by itchyfeet »

Finally fitted the old covers today.

ImageP1060002 by Paul_Barr, on Flickr

hooked on to studs so easy to remove and refit.

ImageP1060003 by Paul_Barr, on Flickr

:ok
Last edited by itchyfeet on 22 Dec 2017, 17:03, edited 1 time in total.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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itchyfeet
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Re: WBX

Post by itchyfeet »

This DG engine has been in the tin top 18 months now, it was a temporary engine while I rebuilt the old DG that had low oil pressure after 90,000 miles. the engine has done about six or seven thousand miles.

The old DG ended up becoming a DJ and then I bought another van with a broken DJ which was more needy and so it got the engine.

The tappets are permanently noisy at idle and when driving at low speeds, they must be worn ( oil pressure on this engine is good) I have reset the preload many times.

I wanted to try changing them but I was reluctant to try the KS tappets because of problems CJH, 123-jn and others have had with the KS tappets draining down when under compression after the engine has stopped.

The KS tappets are a different design to the OEM WBX tappets.

Recently CJH saw these tappets from car parts for less, a bargain at under 70 quid a set and the OEM design, encouraged by the price and the OEM design I was about to buy some when good fortune came my way and todydog sent me a set for free to try.

he is also trying to get them tested for shore hardness.

Thanks tobydog :ok

ImageP1080941 by Paul_Barr, on Flickr


I need to get this lot primed with oil first.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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tobydog
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Re: WBX

Post by tobydog »

Arranged a trip out tomorrow, with a bit of luck should be able to test the Rockwell (HRC) depending on the type of steel/hardening.

If I have time might take a few pics using the Nikon - https://www.nikonmetrology.com/en-gb/pr ... v-vma-4540" onclick="window.open(this.href);return false;
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itchyfeet
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Re: WBX

Post by itchyfeet »

primed/bled these tappets today.

first thing to notice is they are all engraved 09 16 date code I assume

ImageP1090047 by Paul_Barr, on Flickr

clips are different as is the shape of the push rod seat, looks more conical

ImageP1090051 by Paul_Barr, on Flickr

springs a bit different

ImageP1090052 by Paul_Barr, on Flickr

I used assembly lube this time, fill with oil and put spring in

ImageP1090055 by Paul_Barr, on Flickr

plunger in and release the oil I use a small screwdriver

ImageP1090056 by Paul_Barr, on Flickr

pushrod cup/socket in and off to the vice

ImageP1090058 by Paul_Barr, on Flickr

soft jaws are best and a short bolt , I found the vice easier to tighten that with VW OEM tappets which is not a good sign.

Clip in never letting go if it for a second.

ImageP1090060 by Paul_Barr, on Flickr

in a oil bath holes up

ImageP1090063 by Paul_Barr, on Flickr
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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itchyfeet
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Re: WBX

Post by itchyfeet »

I installed these today and I can confirm they are rubbish.

Oil pressure hot was 1 bar at 2000rpm.

Tomorrows job is to put the old ones back.

They say if they look too good to be true......
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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CJH
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Re: WBX

Post by CJH »

Oh dear. What is it that causes the low oil pressure - a loose fit in the bores? Could you tell that as you were fitting them?
"I'm a man of means, by no means....King of the Road!"

1983 Viking Xplorer, 2.1DJ

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itchyfeet
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Re: WBX

Post by itchyfeet »

CJH wrote:Oh dear. What is it that causes the low oil pressure - a loose fit in the bores? Could you tell that as you were fitting them?

Nothing obvious other than they compressed too easily, I think there is some action that pushes a little oil up pushrod tubes so maybe it's exaggerated with too much movement in the tappet.

I just wasted time you wasted money......unless you can return them?

just goes to show low oil pressure can be tappets.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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itchyfeet
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Re: WBX

Post by itchyfeet »

Pics as usual of the process...

rocker covers and push rod tube covers off, remove rocker shaft

ImageP1090064 by Paul_Barr, on Flickr

Pushrods on this side won't just slide out, they hit the pipe ( late cooling system)

ImageP1090065 by Paul_Barr, on Flickr

Telescopic tubes stick and are hard to compress, I made a tool

ImageP1090066 by Paul_Barr, on Flickr

ImageP1090068 by Paul_Barr, on Flickr


when the tubes are compressed you can just change the angle of the pushrods and remove them past the water pipe

ImageP1090072 by Paul_Barr, on Flickr

tappets out with a magnet, positions noted incase I need to refit and submersed in oil

ImageP1090069 by Paul_Barr, on Flickr

assembly lube on new tappets and in

ImageP1090070 by Paul_Barr, on Flickr

pushrods and tubes back, rocker shafts on

I always struggle getting all four pushrods in tappets so I now use a USB camera to be 100% sure, if you are on the edge you damage the tappet and maybe more.

ImageP1090083 by Paul_Barr, on Flickr

TDC no 1

ImageP1090085 by Paul_Barr, on Flickr

slacken off lock nuts and loosen screw to touching, two turns and tighten, rotate engine 1/2 turn clockwise then do cylinder 4, then 1/2 turn 3, 1/2 turn 2

ImageP1090086 by Paul_Barr, on Flickr

ImageP1090087 by Paul_Barr, on Flickr

I left it a while then started and do the break in.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

sarahandthebear
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Re: WBX

Post by sarahandthebear »

Thanks for this itchy I have been teaching myself how these work not being very macanical minded until now I have become very intreasted in engines and I love our 1984 dg. I have been studying websites and the good old Haynes manual teaching myself how it all goes together so anything like this is always a bonus. If you have any other links you think I may be interested in feel free to send them my way. I'm fascinated reading the chats you guys have on the club and hopefully soon I can join in when I feel confident in my knowlage :ok
1984 1.9 dg petrol westfalia joker

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itchyfeet
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Re: WBX

Post by itchyfeet »

sarahandthebear wrote:Thanks for this itchy I have been teaching myself how these work not being very macanical minded until now I have become very intreasted in engines and I love our 1984 dg. I have been studying websites and the good old Haynes manual teaching myself how it all goes together so anything like this is always a bonus. If you have any other links you think I may be interested in feel free to send them my way. I'm fascinated reading the chats you guys have on the club and hopefully soon I can join in when I feel confident in my knowlage :ok

Thanks for the encouragement :ok
Page 1 of my wbxlog thread has links to other rebuild threads.
link to wbxlog in my signature.

Note standard WBX does not have telescopic push rod tubes, I fitted these so that I could swap tappets if needed.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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sarahandthebear
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Re: WBX

Post by sarahandthebear »

Thanks I'll have a good read through that would be fascinated to let you look at our engine I'm still at that stage where I'm a little nervous of taking things apart but I'll get more confident over time I'm sure and you guys are always a great help we always feel like we can ask for help whenever we need merry Christmas
1984 1.9 dg petrol westfalia joker

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itchyfeet
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Re: WBX

Post by itchyfeet »

I checked the old tappets and they are all solid indicating there is nothing wrong with them but they were removed warm.

reinstalled the old ones this morning, always quicker the second time :D , after 2 hours wait for compression to return I just started it and got it hot, oil pressure is resumed :ok

I did notice a spring washer missing of a rocker shaft, dunno why I didn't spot it before, just possible it's the cause of the nagging noise because it would be on the move all the time, I think it sounds better but need to take it for a drive.

rocker shaft comes apart easily, fitted a spring washer from an old scrap head

ImageP1090089 by Paul_Barr, on Flickr

ImageP1090090 by Paul_Barr, on Flickr

ImageP1090091 by Paul_Barr, on Flickr
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

weimarbus
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Re: WBX

Post by weimarbus »

itchyfeet wrote:I installed these today and I can confirm they are rubbish.

Oil pressure hot was 1 bar at 2000rpm.

Tomorrows job is to put the old ones back.

They say if they look too good to be true......

just for comparison what was the previous oil pressure at 2000rpm hot with the old tappets?
1985 hi-top 2.1MV with DG carb and LPG
1955 trials buggy with 1.9 DG high lift cam and twin dell's (now sold)
1972 1303 beetle
1992 Audi 100 2.8 quattro estate
1967 Vw  Madison kit

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itchyfeet
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Re: WBX

Post by itchyfeet »

weimarbus wrote:
itchyfeet wrote:I installed these today and I can confirm they are rubbish.

Oil pressure hot was 1 bar at 2000rpm.

Tomorrows job is to put the old ones back.

They say if they look too good to be true......

just for comparison what was the previous oil pressure at 2000rpm hot with the old tappets?

3.5 Bar at 2000 rpm 80 deg C
The crappy tappets didn't even get to 80 deg C, switched it of at about 70 deg C 1 bar 2000

The annoying tapping noise was the missing spring washer, this engine is still noisier than my DJ but then that has just been rebuilt.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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