WBX 2.1 DJ re-build (with pictures!)
Posted: 25 Jan 2011, 22:56
Hi,
so I am going to completely strip down and (hopefully) rebuild the 2.1 DJ in our camper and thought y'all might be interested in following my progress!
Intention is to make this thread as informative as possible as a thanks for all the info you peeps on the forum have given me since buying the van
Normal rules apply, any advice, thoughts, suggestions, free parts gratefully accepted!
Doing this alongside other work so will try to break the posts down into logical sections to keep the updates going (and save me from RSI whilst typing!!)
History
This is Gunther, purchased on 2.1.11 as our first foray in Vdub land.
Been camping/trailer tenting etc all our lives, parents had loads of motorhomes including a Bilbo but this was our first time. Finances meant it had to be a "project" so was bought knowing it had some bodywork needed and with an engine that was clattering a bit.
On the upside we have loads of history and the van is really solid structurally and in pretty good nick inside - but this thread is about the engine, sooooo
Van is a 1989 Autosleeper with a 2.1 DJ mated to the 3 speed automatic. Van did 95k in first 5 years (may have been a company car) and then 35k in the last 16 years. Same owner for last 13 years and only done about 1k in the last 3 years.
The engine was replaced with an Elite VW unit in 2006 which has done approx 10k (more on this to follow..... )
When we bought it the van had been standing for 4 months and clattered a lot! Low on power which suddenly improved during the test drive (but still noisy) so suspected sticking hydraulic lifters or valves.
Survived the 35 mile drive home OK, pulled reasonably well, no smoke, maintained temperature etc so seemed reasonably solid.
Before stripping I ran the engine for 15 mins with a Wynns additive I use in the Yank motors (my other restoration work) for de-gumming hydraulic lifters etc, replced oil, filters, plugs etc.
Still clattered a lot , so figured this was not going to be a quick fix. Suspicions confirmed by a compression test that showed ~ 150 psi on #1, #2 & #3 but only 35 psi on #4, which sounded like it was loosing compression into the valve cover.
Decided at this point it was an engine out/rebuild job so started gathering info.
so I am going to completely strip down and (hopefully) rebuild the 2.1 DJ in our camper and thought y'all might be interested in following my progress!
Intention is to make this thread as informative as possible as a thanks for all the info you peeps on the forum have given me since buying the van
Normal rules apply, any advice, thoughts, suggestions, free parts gratefully accepted!
Doing this alongside other work so will try to break the posts down into logical sections to keep the updates going (and save me from RSI whilst typing!!)
History
This is Gunther, purchased on 2.1.11 as our first foray in Vdub land.
Been camping/trailer tenting etc all our lives, parents had loads of motorhomes including a Bilbo but this was our first time. Finances meant it had to be a "project" so was bought knowing it had some bodywork needed and with an engine that was clattering a bit.
On the upside we have loads of history and the van is really solid structurally and in pretty good nick inside - but this thread is about the engine, sooooo
Van is a 1989 Autosleeper with a 2.1 DJ mated to the 3 speed automatic. Van did 95k in first 5 years (may have been a company car) and then 35k in the last 16 years. Same owner for last 13 years and only done about 1k in the last 3 years.
The engine was replaced with an Elite VW unit in 2006 which has done approx 10k (more on this to follow..... )
When we bought it the van had been standing for 4 months and clattered a lot! Low on power which suddenly improved during the test drive (but still noisy) so suspected sticking hydraulic lifters or valves.
Survived the 35 mile drive home OK, pulled reasonably well, no smoke, maintained temperature etc so seemed reasonably solid.
Before stripping I ran the engine for 15 mins with a Wynns additive I use in the Yank motors (my other restoration work) for de-gumming hydraulic lifters etc, replced oil, filters, plugs etc.
Still clattered a lot , so figured this was not going to be a quick fix. Suspicions confirmed by a compression test that showed ~ 150 psi on #1, #2 & #3 but only 35 psi on #4, which sounded like it was loosing compression into the valve cover.
Decided at this point it was an engine out/rebuild job so started gathering info.