300CE WBX Repair

[300CE]

Did you have a puller to remove the gudgeon pin Paul? Good to know that the gallery drilling plug looks good

One thing I forgot to mention was one of the piston rings had snapped on one of the pistons so good that I had the new ones.

[itchyfeet]

you can make a puller from an m8 rawlbolt, studding and washers etc.


http://forum.club8090.co.uk/viewtopic.p ... g#p8156269" onclick="window.open(this.href);return false;

[300CE]

you can make a puller from an m8 rawlbolt, studding and washers etc.


http://forum.club8090.co.uk/viewtopic.p ... g#p8156269" onclick="window.open(this.href);return false;

Nice work Paul! It wasn't too much hassle getting the conrod out so all good.

[300CE]

Spent most of this sunny Saturday cleaning all the pistons and heads up as best as possible.

Pistons all cleaned up:

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

As well as both heads:

Untitled by Justin C, on Flickr

Used the old barrel/brake fluid and fine paste technique to remove the scratch from the compression ring area - this worked really well and removed the scratch entirely. Both sides completed with the same amount of turns:

Untitled by Justin C, on Flickr

Springs all cleaned up and refitted:

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

Valves fitted - stems were coated thinly with graphite paste to assist with first time start up:

Untitled by Justin C, on Flickr

New piston rings fitted:

Untitled by Justin C, on Flickr

Mated to it's new barrel - this job was pretty fiddly, but all went well. Piston arrows pointing to the flywheel. The gudgeon pins were removed, cleaned, lubricated and refitted. If you're doing this job make sure that you put some rags in the engine area just in case a circlip should try and make a run for it:

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

Other side fitted:

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

Head side should be fitted through the week - if not it'll be next weekend. I've purchased a new oil pump and gaskets from Brickwerks. I was going to go for the larger heavy duty one but instead opted for a straight forward replacement.

[300CE]

Order for new exhaust just placed:

Untitled by Justin C, on Flickr

[itchyfeet]

I've purchased a new oil pump and gaskets from Brickwerks. I was going to go for the larger heavy duty one but instead opted for a straight forward replacement.

worth measuring the pump body diameter at the cam end, the crankcase opening is about 70.1mm

origional VW pumps I have measured about 70.04 to 70.06

some aftermarket pumps I have measured can be as low as 69.90 ( hence the need for o ring)

also check the gasket thickness to cover plate and consider leaving it out and using sealant like Curil T after checking endfloat, fettle pump body or gears if needed.

no guarantee a new pump will be better pressure, it coukd be worse if the pump tolerances are poor.

[300CE]

Many Thanks for the info Paul - i got a genuine VW gasket from Brickwerks and checked with them on the pump itself which they use regularly on the buses they have in without issue, but like you said it's worth checking as it'll be no good if the tolerances on the new one are out. Will check out the measurements. I was also looking at the Gene Berg one over in the US:

http://www.piersideparts.net/mm5/mercha ... y_Code=GBE" onclick="window.open(this.href);return false;

and I found a 26mm one in the UK for sale at RJ Volks Performance (they've confirmed that it fits the WBX), but it was just too much at £115.00:

http://www.rjvolksperformance.com/berg- ... -used.html" onclick="window.open(this.href);return false;

[300CE]

Further continuation of putting the other side of the engine back together today. Rockers all stripped and cleaned:

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

Piston rings fitted and then put into new barrels:

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

Gasket and sealant added, Hylomar AF put onto the barrels:

Untitled by Justin C, on Flickr

Compression rings fitted to head and Hylomar AF brushed on:

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

Head fitted and yellow sealant placed on nuts then torqued at 25nm, 40nm & finally 50nm. Push rod tubes also fitted:

Untitled by Justin C, on Flickr

Rockers fitted and then set:

Untitled by Justin C, on Flickr

Water pump put back on - also fitted new stainless exhaust studs to the block ready for fitment of the new exhaust.:

Untitled by Justin C, on Flickr

Engine has now been taken back to mine ready for painting. I'm going to invest in a new water pipe to water pump and the small piece to the engine block as mine looks a little bit worse for wear.

[300CE]

Painted the block today - going to paint the engine bay as well as the lump's out. Engine bar, front bumper and engine lid have been sent off for powder coating. I'll then be painting the front grille's and door handles. Engine will then be ready to go back in and then road tested:

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

Untitled by Justin C, on Flickr

[Cobra88]

Looks lovely mate

[itchyfeet]

looks great

have you got a job lot of that paint, looks the same as the bench

[300CE]

Cheers chaps!

have you got a job lot of that paint, looks the same as the bench

...same as the van as well!!

[123-jn]

Does anyone else use some hylomar on the compression seals? I have used a very thin smear on both sides in the past, some say not to? There seems quite alot on the picture?

[itchyfeet]

Does anyone else use some hylomar on the compression seals? I have used a very thin smear on both sides in the past, some say not to? There seems quite alot on the picture?

It was reccomended by tencentlife he is a respected rebuilder in USA
I asked on the facebook WBX group and general feedback is its not needed but it will do no harm

I used it because heads were scratched and ground with a barrel so surfaces not A1

link to my thread here and a link on my thread to tencentlifes coments

http://forum.club8090.co.uk/viewtopic.p ... 5#p8171355" onclick="window.open(this.href);return false;

[300CE]

Howdy 123, as per Paul’s reply, tencentlife originally replied to my message about overpressurising and I also had to grind the heads slightly due to a scratch which may or may not have been the original cause of the problem.

Paul’s been using his rebuilt engine with the Hylomar without incident so fingers crossed my issue will have been resolved but only time will tell