WBX

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

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itchyfeet
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WBX

Post by itchyfeet »

Today I have been reassembling a WBX.
Love em :ok

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 :D )
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;
Last edited by itchyfeet on 02 Feb 2017, 17:54, edited 17 times in total.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

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silverbullet
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Re: WBX

Post by silverbullet »

Excellent. Another one of us with true faith ;)

Sent by Morse code from the bunker
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

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300CE
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Re: WBX

Post by 300CE »

New one to go in Paul or are you rebuilding your current one?
'86 DG, Weber Carb

Jawin89
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Location: Gloucestershire

Re: WBX

Post by Jawin89 »

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.

:D
1989 1.9 WBX pop top

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itchyfeet
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Location: South Hampshire

Re: WBX

Post by itchyfeet »

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.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

User avatar
itchyfeet
Posts: 12385
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Location: South Hampshire

Re: WBX

Post by itchyfeet »

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.

:D

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?
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

Jawin89
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Location: Gloucestershire

Re: WBX

Post by Jawin89 »

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 :ok
1989 1.9 WBX pop top

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itchyfeet
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Re: WBX

Post by itchyfeet »

Don't suppose you did a rebuild thread?
I have stuck some links on the op^^
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

Jawin89
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Joined: 01 Feb 2014, 09:04
80-90 Mem No: 13200
Location: Gloucestershire

Re: WBX

Post by Jawin89 »

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.
1989 1.9 WBX pop top

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kevtherev
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Re: WBX

Post by kevtherev »

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

Image
2.1 DJ on pierburg + LPG

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itchyfeet
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Re: WBX

Post by itchyfeet »

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

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

ImageP1040632 by Paul_Barr, on Flickr
Last edited by itchyfeet on 22 Dec 2017, 15:40, edited 1 time in total.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

User avatar
itchyfeet
Posts: 12385
Joined: 23 Jul 2007, 17:24
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Location: South Hampshire

Re: WBX

Post by itchyfeet »

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?

ImageP1040624 by Paul_Barr, on Flickr

second thing... Tappets don't look square to the case?
ImageP1040613 by Paul_Barr, on Flickr
Last edited by itchyfeet on 22 Dec 2017, 15:41, edited 1 time in total.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

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silverbullet
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Re: WBX

Post by silverbullet »

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
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

User avatar
itchyfeet
Posts: 12385
Joined: 23 Jul 2007, 17:24
80-90 Mem No: 12733
Location: South Hampshire

Re: WBX

Post by itchyfeet »

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;

ImageP1040641 by Paul_Barr, on Flickr
Last edited by itchyfeet on 22 Dec 2017, 15:42, edited 1 time in total.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
itchylinks

User avatar
silverbullet
Trader
Posts: 13428
Joined: 08 Jun 2009, 09:51
80-90 Mem No: 6908
Location: Surrey Syncronaut #156
Contact:

Re: WBX

Post by silverbullet »

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
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

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