Did Vw Line bore there own stamped DJ rebuilds?

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

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itchyfeet
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by itchyfeet »

Strip it and measure up. even if main bearings are NLA they may be good enough to reuse. Mains seem to last well, built like brick "pooh". People tubo these up to several hundred BHP
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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itchyfeet
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by itchyfeet »

I just checked min order is 1000 sets at 75 euros a set. You would have thought thats not a huge sum for a Company like Heratige or Brickwerks. Can make 100% profit on that.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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spanishfly
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by spanishfly »

Does seem like if we wait long enough the NLA unicorns will come back to graze.

In the meantime I've run the Dehler up to temperature driving around with brisk acceleration up to 4000 revs and a bit of idling for 10 minutes until the temp gauge stabilised in the middle (this may not count as hot hot? ) but have recorded the oil pressure which was:

               cold 4.25 bar (kp/cm2) @ 900 rpm the same at 2000 and 3000
after 10 mins  1.25 bar @ 1000
                       3      bar @ 2000
                       4     bar  @ 3000 

I've swapped the sender over to the problematic syncro and when postie delivers the Audi gt 5 bar gauge (presuming it works) will repeat and carefully record minutes elapsed to buzzer . If it doesn't I'll fiddle about under the dash and swap the VDO gauge from the Profi.

Then I'll feel justified in dropping it, stripping it and moving to the next level of T3 ownership! 
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

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937carrera
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by 937carrera »

1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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itchyfeet
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by itchyfeet »

10 mins is not enough for hot oil but your figures imply it's not too bad or it's a wiring fault so I'd say safe to give it a run for 20 mins and test again if not too bad get it stinking hot and test again.

spanishfly wrote: 07 Sep 2020, 17:16 Does seem like if we wait long enough the NLA unicorns will come back to graze.

In the meantime I've run the Dehler up to temperature driving around with brisk acceleration up to 4000 revs and a bit of idling for 10 minutes until the temp gauge stabilised in the middle (this may not count as hot hot? ) but have recorded the oil pressure which was:

               cold 4.25 bar (kp/cm2) @ 900 rpm the same at 2000 and 3000
after 10 mins  1.25 bar @ 1000
                       3      bar @ 2000
                       4     bar  @ 3000 

I've swapped the sender over to the problematic syncro and when postie delivers the Audi gt 5 bar gauge (presuming it works) will repeat and carefully record minutes elapsed to buzzer . If it doesn't I'll fiddle about under the dash and swap the VDO gauge from the Profi.

Then I'll feel justified in dropping it, stripping it and moving to the next level of T3 ownership! 
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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spanishfly
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by spanishfly »

Blimey, I really am a rank amateur! Very comprehensive, guess I need to know more about the oil temperature.

Those measurements were from my Dehler, a barn find bought for working away from home as the head room makes lonely nights more doable. Several months detective work suggest it had a DJ Oettinger but now has MV ECU, no white box cat and probe (perhaps the Oettinger 2000E variant always did?) and about 3000 miles under its belt.

I'm attempting to learn more about its health and fluid dynamics whilst using it as a benchmark to compare with the (probably low oil pressure) barn find Syncro.   

 
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by tobydog »

Tribology 8)
Knowledge is power
1970 CU

spanishfly
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by spanishfly »

Tx, that right there is a top crozzie clue to be filed for the required moment. Curiously nonechoic though!
 
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

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itchyfeet
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by itchyfeet »

spanishfly wrote: 07 Sep 2020, 20:45
Those measurements were from my Dehler


So have you measured the suspect engine yet?
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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spanishfly
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by spanishfly »

Awaiting postie! Will do it today.
 
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

spanishfly
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by spanishfly »

No sign of postie so swapped sender and gauge into the syncro for consistency and repeated the test on the suspected low pressure DJ engine.

Cold                2@1000               4 @ 2000
Warm/hot    0.3@ 1000               2 @ 2000 

red light flashing at tick over after running 10mins at 2500 rpm
Not flashing at 2000 though I'm sure if I got it stinking hot it probably would be....! 

Doesn't look good??

Other things: seemed to be very rich lumpy black smoke whilst warming up which it didn't do before but has sat for 6 months
Dash is a rewired Chris dash never used on the road but I think I made the right connections, all seems to work

Dops sender is grey I think
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

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937carrera
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by 937carrera »

I agree, it doesn't look brilliant.

Grey "high" switch is 0.9 bar, so the later fitment to stop customers bothering the main dealer asking for free engine rebuilds, so the buzzer willl remain silenced

The 2 bar at 2000 rpm actually looks good compared to the 0.3 bar on "idle" reading, which is what it will read when the engine finally gives up.

I presume that water temp was up at the LED after the 10 minute warm up, in which case these are "up to temperature" readings, probably corresponding to oil at 80-85 degrees C
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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itchyfeet
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by itchyfeet »

What is the gauge and sender. electric gauges can be inaccurate. better to fit a wet gauge and repeat.
Does sound like it needs a rebuild.
1988 DG WBX LPG Tin Top
1989 DJ digijet WBX Holdsworth Villa 3 Pop Top
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spanishfly
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by spanishfly »

Grrrr! Thanks. Yes up to the led so up to temperature. The gauge is a NOS VDO cockit 0-5 kp/cm2, the sender is old not sure what though a NOS 5 bar VDO should arrive later this week. Will wet test once I've found a tester. There is clearly a sizeable difference between the apparently low mileage rebuilt one that Aidan suspects was one of the last Vw rebuilds from 2010 and the Syncro one using the same sender and gauge. 
Had to happen one day. 
I'm probably repeating myself but are there any essential measuring or other tools needed aside from a normal fairly comprehensive T3 tool kit? Things I can scour the net for 2nd hand?
Cheers
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

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937carrera
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Re: Did Vw Line bore there own stamped DJ rebuilds?

Post by 937carrera »

It depends how much you want to get into the detail and analysis really

Torque wrench(s)
Puller to get main bearing 4 off
Vernier caliper
Dial gauge
Micrometer
Bore gauge

You need the first, the rest of the list is in decreasing order of need.... depending on the rebuild standard you want

Off the top of my head anyway
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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