Club 80-90 Forums

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

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.

Finally fitted the old covers today.

P1060002 by Paul_Barr, on Flickr

hooked on to studs so easy to remove and refit.

P1060003 by Paul_Barr, on Flickr

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

P1080941 by Paul_Barr, on Flickr


I need to get this lot primed with oil first.

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;

primed/bled these tappets today.

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

P1090047 by Paul_Barr, on Flickr

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

P1090051 by Paul_Barr, on Flickr

springs a bit different

P1090052 by Paul_Barr, on Flickr

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

P1090055 by Paul_Barr, on Flickr

plunger in and release the oil I use a small screwdriver

P1090056 by Paul_Barr, on Flickr

pushrod cup/socket in and off to the vice

P1090058 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.

P1090060 by Paul_Barr, on Flickr

in a oil bath holes up

P1090063 by Paul_Barr, on Flickr

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......

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?

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.

Pics as usual of the process...

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

P1090064 by Paul_Barr, on Flickr

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

P1090065 by Paul_Barr, on Flickr

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

P1090066 by Paul_Barr, on Flickr

P1090068 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

P1090072 by Paul_Barr, on Flickr

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

P1090069 by Paul_Barr, on Flickr

assembly lube on new tappets and in

P1090070 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.

P1090083 by Paul_Barr, on Flickr

TDC no 1

P1090085 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

P1090086 by Paul_Barr, on Flickr

P1090087 by Paul_Barr, on Flickr

I left it a while then started and do the break in.

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

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

Thanks for the encouragement
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.

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

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 , after 2 hours wait for compression to return I just started it and got it hot, oil pressure is resumed

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

P1090089 by Paul_Barr, on Flickr

P1090090 by Paul_Barr, on Flickr

P1090091 by Paul_Barr, on Flickr

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?

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.