2.1 DJ refurbishment (contains crankshaft nudity)

[kevtherev]

After purchasing a DJ 2.1 I am about to embark on a voyage of discovery
the engine has been sat in a damp shed of doom for a while and came with a smoky No.1 cyl. Suspected oil scraper ring. No drama there then.. piece of cake

So we begin....
here she is.. all oranged up, stripped cleaned and ready for the head to come off




with the exhaust removed and the head nuts off the head was withdrawn from the cylinders




leaving me this fine sight




Bit of moisture ingress I think

once the liners were removed I could see a problem with the pin, it shouldn't be there
the base of the piston had took a beating too.



The pin had travelled to meet it's bore where it tried to dig it's way out.



the head was cleaned and no damage was found.



both liners however were shagged, so they will be replaced along with the pistons pins and clips



the other side feels smooth so I am loathed to remove the head.
However as I will be replacing the liners,pistons and stuff I suppose I ought to.
what do you think?

[Mocki]

so was that caused by the circlip missing from the end of the guden pin, or by it jumping off and is it still lurking in the bottom end somewhere?
Are you having new liners????
can we wiki that up there???

[billy739]

hi, had exactly the same on an engine a few years ago , strangely i bought it and was told ' recently had a rebuild on the engine'

looks like yours isant original either , judging by paint and pushrod tubes!

[Fritz]

I've had one of those on an Escort engine when I first started in the fitting game some years ago , mine also needed a new liner and the piston pin re fitting properly.

The dis heartening thing was it was one I had re built,,,,


Regards,


Fritz,,,,,,

PS, I have a good 3/4 of a tube of the Loctite High temp sealer you will need to put it back together, if you want it let me know....

[kevtherev]

so was that caused by the circlip missing from the end of the guden pin, or by it jumping off and is it still lurking in the bottom end somewhere?
Are you having new liners????
can we wiki that up there???

OK thanks for the replies lads.
I don't know whether the clip is in the bottom or not.
I do know that the piston skirt is damaged, conducive to debris between the liner and piston. Therefore the evidence tells me it is in the bottom.
As the pistons were re-ringed 1500m ago I'm not sure if the piston was removed for re-ringing either.

So my question remains, should I undo the remaining bank and change the liners?

please wiki as required ... more pics to follow

[billy739]

this far in and your spending money , YES strip it down .
you need to know all 4 are good , and besides piston rings come in sets of 4!

good to know the other gudgeon pins are in place and not wearing the liners the other side!

are you changing the big ends whilst you have it this far apart?
good idea as you have it this far?
dont need to split the block

[Ian Hulley]

So my question remains, should I undo the remaining bank and change the liners?

Who know's what horror lies within ..... be afraid be VERY afraid. What's the crankshaft and tappet journals like ?

Ian.

[jamesc76]

I would strip it right down do as many seal's bearings as you can then you know its a good un!!! Good work young man!

[kevtherev]

Thanks Billy
so renew all... liners pistons pins and clips on both sides.
To be fair I was considering it anyway, just wanted a shove!

I may well split the crank now as a matter of course.. so mains are on the menu
This is un-walked territory for me, never been further than mains/ends

Could you or some one tell me what are the part Nos. for the pitons pins clips and liners... just to save time at VW?

[Ian Hulley]

Could you or some one tell me what are the part Nos. for the pitons pins clips and liners... just to save time at VW?

I wrote them up some 6 months or so ago in Technical ..... except the pistons and barrels. Wade through the drivel I've posted ... it's there somewhere.

Ian

[T'Onion]

bugger , sorry Kev , I'll bring you some more liners and if i can a replacement piston or two if i can find them
Looks like the shed of doom is leaking more than I realise
I'll also speak to you about the price that you paid

[purpletony]

Hi Kev
Do yourself a favour only use Elring or genuine VW gasket setsdont use the gsf sets Heinze or sumet like that as they are crap ive had 3 head gaskets go on 2 different rebiulds all failed in the same place

Tony

[Simon Baxter]

I have a brand new set of 2.1 DJ barrels and pistons I got in for doing a job that didn't materialise.
They are Kolbenshmidt ones, not the cheaper Mahle ones from GSF (not that there is anything wrong with them)
Anyway, from what I gathered it was the last set from Germany.
Sat on the shelf and can be sensible money if needed.
I can also get AMC cylinder heads too, again if needed.

[T'Onion]

ps yes the pistons were removed , looks like i didnt seat the clip correctly on that one , Kev pull the over side , just in case water has got in there as well

[kevtherev]

I have a brand new set of 2.1 DJ barrels and pistons I got in for doing a job that didn't materialise.
They are Kolbenshmidt ones, not the cheaper Mahle ones from GSF (not that there is anything wrong with them)
Anyway, from what I gathered it was the last set from Germany.
Sat on the shelf and can be sensible money if needed.
I can also get AMC cylinder heads too, again if needed.

thank you simon I will take them off your hands, I could do with the heads too, I also need the clips and a tool to fit them if you can help with that, as the haynes describes a tool to remove the pins too, which I need. The pin has peened over so can't be removed in the conventional way.

Shall I PM you on Brickyard, or put in a request by e-mail?

hoi mark!
look pal these things happen.. I'm not at all bothered, you told me what you knew, so thats that innit?