New Amateur Engine Rebuild Featuring a DJ2.1

[maxstu]

I'm starting another non-pro (reads as limited ability numpty) rebuild for the forum. It will not be as photo intensive as previous rebuild posts. Yet will take in pertinent points to aquaint forum users' of the amount of detail and work it requires to take one grotty snotty WBX engine and restore it to some sort of reliability.

More details shortly.....

[maxstu]

I shortlisted a few companies to do the work of regrinding a damaged DJ crank. Unfortunately one company is no longer trading in that area. And the other, specialising in V8's, did not have a grinding wheel narrow enough to fit. What a great start!

That left me with Southern Rebore two hours drive away. Or, very reluctantly, nearby Thanet Engine Services (the ones whom last time chiselled off the dissy and cam drives from the crankshaft). And as the latter can do all the work of regrinding and polishing, plus ultrasound cleaning the cases and heads, l opted to use their reasonably priced services again. Fingers are well and truly crossed.


So l stripped the engine of all components, including oil strainer in the sump and the relief valve. But the top part of the valve, above the spring, refused to fall out. Under scrutiny of a torch this item was blocking it. Not a good start!

Brick bolster and hammer to remove relief valve cover.



Rubber item found above spring.






All bagged and boxed...

Cases and heads for cleaning





Crank for grinding and polishing. I have removed the dissy and cam drives myself this time. With the proper tool.

[Aidan]

so what's the broken bit - can't work it out myself, is it metal or plastic ?

[silverbullet]

Whatever it is, it should be in the crank case oil gallery!

PS I always use an impact driver to remove and refit the pressure relief valve cap.

[maxstu]

Whatever it is, it should be in the crank case oil gallery!

Me no comprendo? Do you mean bits could be found in crank case oil gallery, too?

[maxstu]

so what's the broken bit - can't work it out myself, is it metal or plastic ?

Very heavy duty rubber glove consistency feel to it.

[maxstu]

Whatever it is, it should be in the crank case oil gallery!

Me no comprendo? Do you mean bits could be found in crank case oil gallery, too?

And to answer my own question..l have just remembered l did take these poor quality photos...

[tobydog]

so what's the broken bit - can't work it out myself, is it metal or plastic ?

Very heavy duty rubber glove consistency feel to it.

Could be a ............ rubber glove?

[Stesaw]

Sealant perhaps stu.

[maxstu]

Sealant perhaps stu.

Could be. I can't tell. Will see if l can dig it out of garage bin tomorrow.

[tobydog]

https://www.boedeker.com/Portals/0/Docu ... i-burn.pdf

 

[maxstu]

Not sure what it is. The moulded curving edge is approx. 2cms. Some kind of rubber diaphram. Or a heavy duty rubber glove? It could well be the reason for the conrod bearing destruction?

[maxstu]

I received a call from Thanet Engine Centre yesterday. Likely crankshaft needs grinding on conrod journals to US .5mm to rid it of damage caused by bearing going walkabouts. Then a polish. And crank main journals will also need grinding to US .25mm. Then a polish.
Also, a small mark on the camshaft caused by the thrust bearing may (hopefully) polish out.
What are my options if camshaft needs more work than just a polish?
Also what does this symbol mean on the old thrust bearing? Standard size?

[Stesaw]

In regards to the camshaft, I got a new one from Andrew, sent him my cam wheel and he bolted it up to the new cam and sent it back.
Not sure if he will still have any but worth the ask I suppose Stu.

[maxstu]

In regards to the camshaft, I got a new one from Andrew, sent him my cam wheel and he bolted it up to the new cam and sent it back.
Not sure if he will still have any but work the ask I suppose Stu.

Noted with thanks, Steve.