Club 80-90 Forums

Ok, so I’ve finally accepted what has been abundantly obvious to you all for months and months……..I’m never going to complete this engine rebuild. Many reasons for this - primarily, I’ve sold my van and therefore don’t have anywhere to put a rebuilt 2.1DJ engine (not sure it’d be an ‘upgrade ‘ in th...

As unbelievable as this may seem (not least, to myself) there is a high probability that this thread will be resurrected in the near future…… I have completed the complete renovation of my house and find myself with spare time and a garage full of engine bits. If you’ll just allow me the time to rea...

Yes - had the same problem for ages. Changed the gasket, changed the studs, tried all different types of nuts and it still leaked.
Then used a thin smear of Curil-T on the gasket and that solved it.


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Mine were absolutely butchered but I managed to use a dremel and cut a slot in the top to allow me to use a flathead screwdriver to get them out. Plenty of Plusgas applied before trying to spin them. Best of luck

As above - Brickwerks do all the bushes etc that will need replacing. The guide in the Wiki is excellent and covers all types. I followed it when I stripped my complete linkage and now my gear shifts are as smooth as a modern car. Have to say that I luckily have the use of a ramp which made the whol...

A new (old) house - I am in the middle of a complete house renovation and currently living without a kitchen or bedrooms for the kids! There is light at the end of a very long tunnel and, fingers crossed, I will be back on this rebuild in a couple of months...... Think I’ll have to reread it a coupl...

All interesting reading, gents - appreciate all the input. It appears that the next stage is to examine (and post a few pictures) of the corresponding valve seat and also further investigation of the cracks. It’s now a given that a new set of valves are required- this seems a reasonable thing to do ...

Good to hear you are back at it! Personally I would replace all of the valves (or at least the exhaust valves as a minimum). They have a very hard life and are prone to failure and aren’t that expensive (around £80 all in). Saves you some cleaning time too!! I don’t know if the difference in ring w...

Section 5: Lapping the Valves From Wikipedia: Lapping is a machining process in which two surfaces are rubbed together with an abrasive between them. Definition of ‘Lap’ (about the 5th one down after running or cats drinking milk...) - Polish metal, glass or a gem. As far as I can work out the idea ...

Section 4 (Revisited): Removing the Valves and Cleaning When the valves were removed from the Heads they were all separately bagged and labelled with the corresponding springs and collets. https://uploads.tapatalk-cdn.com/20191110/a44602d6692471682245756502e2f12e.jpg Each valve has a build up of har...

Well, August turned into a particularly long month...... Apologies for the lack of updates - it’s because there has been nothing to write about. I’ve managed precisely zero minutes on the rebuild as the past few weeks have been mostly about moving, roofing and internal destruction...... I may start ...

Much appreciated! Actually away in the van as I type - back in the middle of next week then it’s time to clean the case and lap the valves.
Hoping to get a couple of days on it before the end of the month....


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Thanks everyone- the support means a lot. Unfortunately, August is going to be a very slow month. I’m actually going to get to use the van for some camping, we move house in the middle of the month and, I suppose, I’ll be expected to do some parenting whilst the kids are still off school. It’s a bit...

The downside being that it has opened up a whole new world of cleaning...... And dirty fingernails for weeks. Keep going, I am with you every step you take. Well done. Thanks for the support - it’s good to know that at least someone is reading this rubbish! (Think I must have contributed at least h...

Took the shed for a good old drive around yesterday- all seems to be good. Oil pressure gauge is definitely lower than ideal but DOPWS didn’t sound and it drove as well as could be hoped (when you’ve removed a DJ and put in a DG) After the tests earlier in the week I’m happy that DOPWS is functionin...