Club 80-90 Forums

Today I have been reassembling a WBX.
Love em

some WBX rebuild threads you may be interested in...

1.9 DG - Attempting a full rebuild...T25Convert
http://forum.club8090.co.uk/viewtopic.php?f=37&t=120790" onclick="window.open(this.href);return false;

Edna's new MV build - wbx pervs only! silverbullet
http://forum.club8090.co.uk/viewtopic.php?f=4&t=99380" onclick="window.open(this.href);return false;

2.1 MV Rebuild DG case!!! 123-jn ( Actually a DJ build)
http://forum.club8090.co.uk/viewtopic.php?f=37&t=148330" onclick="window.open(this.href);return false;
http://forum.club8090.co.uk/viewtopic.php?f=37&t=153699" onclick="window.open(this.href);return false;

Early 1.9 to 2.1 conversion - stop me if I'm being stupid! CJH
http://forum.club8090.co.uk/viewtopic.p ... 9#p7990928" onclick="window.open(this.href);return false;

PetenAli's WBX 2500 engine build. silverbullet
http://forum.club8090.co.uk/viewtopic.php?f=12&t=142235" onclick="window.open(this.href);return false;

WBXlog ( me)
http://forum.club8090.co.uk/viewtopic.p ... 22&start=0" onclick="window.open(this.href);return false;

WBX Cyliner heads reseal ( me again )
http://forum.club8090.co.uk/viewtopic.php?f=37&t=156223" onclick="window.open(this.href);return false;



2.1 WBX engine rebuild noob.... (sherlylock)
http://forum.club8090.co.uk/viewtopic.php?f=37&t=146855" onclick="window.open(this.href);return false;

1.9 to 2.1 DIY upgrades...
http://forum.club8090.co.uk/viewtopic.p ... 0#p8142348" onclick="window.open(this.href);return false;

tappet adjustment - Meggles
http://forum.club8090.co.uk/viewtopic.p ... 92&start=0" onclick="window.open(this.href);return false;

Oil pressure problems...
http://forum.club8090.co.uk/viewtopic.p ... 1#p8129303" onclick="window.open(this.href);return false;

A handy little web page for wbx fans
http://forum.club8090.co.uk/viewtopic.p ... 25&start=0" onclick="window.open(this.href);return false;

2.1 workshop manual
http://syncrosport.com/info/manual/VW_T ... hanics.pdf" onclick="window.open(this.href);return false;

3 bolt cams with adapters to four stud WBX gears
http://forum.club8090.co.uk/viewtopic.php?f=12&t=140840" onclick="window.open(this.href);return false;

Excellent. Another one of us with true faith

Sent by Morse code from the bunker

New one to go in Paul or are you rebuilding your current one?

I overhauled my WBX and fired it up for the first time yesterday. Just need to bleed the coolant system now and set the timing properly.

300CE wrote:New one to go in Paul or are you rebuilding your current one?

This is a Circa 1997 VW recon I bought with a snapped head stud, I wanted heads for mine a few years ago.

I have changed the head stud (what2do removed the old one) and reassembling with one of my old heads and another I bought, I didn't split the case.
It's a low cost cobble up to stick in the van while I do mine, it all looks to be in pretty good shape including cam, fingers crossed.

Jawin89 wrote:I overhauled my WBX and fired it up for the first time yesterday. Just need to bleed the coolant system now and set the timing properly.

Nice one, seems like more people prepared to do this themselves these days, did you go the whole hog or was it a freshen up?

I was going to just freshen up but ended up going to whole hog, barrels/Pistons, bearings etc. I got hold of a VW nos cam from heritage although the first one they sent was pitted and rusty so they replaced it. Also replaced all the fuel lines whilst i was at it.

First road test will be next weekend

Don't suppose you did a rebuild thread?
I have stuck some links on the op^^

I did photograph everything and just need to put them together on p bucket. I will see if I can get something posted this week.

I'm replacing head seals, so far so good.

love the piece of cardboard with pushrods in them Kev, I have one the same

So here is where I finished today,

Barrel lower sealing surfaces cleaned until my fingers and knuckles ( bashed on the studs) hurt.
Pistons and barrels back in ( easiest to fit gudgeons with the engine sitting on the flywheel)
Crank end float checked ( need to order a shim)
Gearbox input shaft needle bearing replaced
Tappets removed cleaned replaced
New oil pressure relief valve spring
head to barrel sealing surfaces cleaned ( very time consuming)
valves ground
All threads cleaned with taps
all studs wire brushed

Next step to fit heads and oil pump

P1040632 by Paul_Barr, on Flickr

Two things I noticed this weekend are

These holes are drilled right through, same on all WBX I think ( I checked two other cases I have)
This means there must be a way of sealing these, alternator studs often strip out so if you can drill right through you can fit new studs but how do you seal them?

P1040624 by Paul_Barr, on Flickr

second thing... Tappets don't look square to the case?
P1040613 by Paul_Barr, on Flickr

1. Loctite 542 hydraulic seal
2. Tappet bores are at 90 degrees to crank/camshaft centreline but tube seal seats are cut on an angle to compensate for angled pushrods.

Sent by Morse code from the bunker

Thanks I will check that Loctite out, I guess the threads need to be tight for it to work, perhaps VW used interference threads.

Another observation from two cams pulled from two engines, Both -1 is this a common size, or coincidence?
I want to buy one from VHW before they sell out but they don't list sizes. I suppose you could have them swapped by a local machine shop if you pull your cam and it's an odd size

https://www.vwheritage.com/shop/type25- ... StartRow=1" onclick="window.open(this.href);return false;

P1040641 by Paul_Barr, on Flickr

Pure coincidence. The tolerances ranged from +5 to -5 but tbh when using a worn drive gear its only a guide (believe it or not, the alloy gear picks up particles and actually wears the steel one, not the other way round!)
I am always after used cam gears btw...

PS the difficult thing is getting the rivetting done to an acceptable standard. Its a disappearing art.
They are 6mm so resorting to a bolt-on requires M7 × 1 screws, and that makes them a special. Been there, investigated that.

Sent by Morse code from the bunker