PetenAli's WBX 2500 engine build

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That's cold cranking on 15w40 oil, plugs out and with a weedy 091 short-body starter.
Reasonably pleased with that.
Not impressed with the aftermarket new rocker covers though, they clearly are not flat at all and leaked just doing this test! Utter rubbish! I will freshen up a pair of genuine VW ones.

[PetenAli]

That pressure looks not bad at all. Do we need some quality cast aluminum rocker covers?

[silverbullet]

Well given that it was spinning pretty slowly as things go, I would hope for more like 60 cold, so thats a solid 4 bar.

I cant believe that these rocker covers dripped literally within a minute. Very poor.

If you fancy some alloy ones Pete then get them to me asap! I take it that they are clip-on or are they 2-stud type 4 jobbies?
The latter means a lifter pre-load reset.

I am just waiting for the collective's DJ spares cache to get to me, then I wil have a TCI to make some sparks

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PS I suspect that the oil cooler still has a lot of air in it, so that may be factor in the way it builds oil pressure. The filter was primed first, then after two cranking sessions to get that gauge pressure it made some quiet creaking and burping noises inside which I presume to be the air being pushed out of the oil galleries!
I still need to paint the cooler ducting too, its a bit chicken & egg but thats how it turned out.
Not long now...

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PPS Want to go all-out and have some new bale clips for the covers too?

[PetenAli]

Package on its way to you. Sticking with original black for the time being - clean and hopefully oil tight. New clips also.

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If not already aware, I will bring this to Brickwerk's attention.

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I resorted to Reinzosil!

(The new clips were a lot more positive too, the old ones I could push on by hand)

Next wiring question: I have either got mixed up with the info Andrew posted or got myself confused.

To what does this red/white and Brown/green wiredr plug connect, very close to the AFM plug?

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Its a DJ auto loom circa 1988 so is this the starter inhibit switch connection?

[syncroandy]

Hi Ian, the 2-pin connector near the AFM is for the fuel pump.

[silverbullet]

Thanks! That is what Andrew said before. Got myself well mixed up. So there must be another bit of missing wiring to run down to the pump.

The engine is now festoonwd with hoses and bungs, so should hold coolant for a test.

My spare efi pump turns out to be either seized or gummed up with old petrol residue, now soaking in brake cleaner...

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Needless to say the Book of Lies doesnt cover Digijet/Digifant wiring in full...

[Johnnyace]

Hi gents, regarding rocker covers, stick to stock, period, I've been there! Lots,,,, you should be able to source Beetle VW Brazil covers, at a push, Euro car parts pattern ones are acceptable, they do the bailes also, if you really do want chrome, Scat clip ons are good, they have internal gasket retaining tabs to stop gasket creep, they are deeper than stock so be sure the come with the correct bailes, they use stock gaskets, only use Elring, either German or USA version, they are the only ones that fit properly and don't creep, the best bolt on alloy covers are CSP, expensive but use a non stock 'u' channel gasket, no likey, scat alloy bolt ones are ok and and have anti creep 'craters' on the gasket rail and use stock gaskets, most other after market covers are to be avoided, they just don't fit and are 'pre warped to guarantee oil leaks' . VW Heritage should have the Scat covers, Best regards Johnny.

[silverbullet]

It seems that you need to replace clips and covers together. The old clips were too easy to fit over the repro maybe they flatten out a bit after 30 years...
I might put some Scat ones on my own engine based on that.
Thanks for the tip!

[PetenAli]

Have the BW covers and clips arrived?