DJ2.1 Rebuild

[maxstu]

Nice work Stu!! Not long now mate.

Cheers, Justin.  

[Smiffo]

In my opinion, the easiest readings, for an amateur such as myself, come from following Itchyfeet's offerings. Great photos and concise information....unlike my inane twitterings. I sorely missed his imput during this rebuild.

My thanks to all contributors on this post.

Couldn't agree more. So much can be learnt from posts here from the 'old timers' and their contribution is under appreciated somewhat perhaps. ( Generally speaking of course. )

Speaking of which; where is Itchy?
Is he still camper van-ing?
 

[Stesaw]

Pretty sure hes quite active on facebook groups,unless im mixing people up...
Great job stu, i agree with itchys posts they were my go to for deciding. When i did my thread, turns out its very difficult to document everything with pictures as you go and to do it clearly, as you say numpty ramblings

The rotating engine stand makes seating the pushrods a doddle. Easy to set the rocker adjusters too while your at it so no faffing about under the van.

[ajsimmo]

I've never thought of putting the sealant on the case first, I always run a bead around inside the seal. Didn't it get messy slipping the seal over the sealant?
Also, I've never thought to rotate the engine to horizontal to fit the head, then fit pushrod tubes with pushrods to hold them in! It's either a stroke of genius, or a massive faff, not sure which. I just stand the tubes up vertically, then stick the head on, letting gravity help rather than hinder. Nuts on with yellow sealant to just nipped, wiggle head to check seating/spread sealant, 10, 30, 45, 50 a couple of times round, have a cuppa then back for a final 50 once it's "settled". Happy.

Anyway, I'm certainly not criticising, looks like you've done a cracking job.

Sent from my moto g(30) using Tapatalk

[maxstu]

Thanks, Andrew. I won't be going pro that's for sure. However, there is often a very fine line between genius and a massive faff!

Yes, that makes better sense adding sealant inside of the seal instead of along engine block. Noted for another time...if there is one!

And many thanks for your support over the last seven months.

[maxstu]

On with the rocker shaft on both sides. On each head studs add wavy washers and nuts then torque to 25nm.

Slacken the rocker arm nuts and release the adjusting screws. Set timing by rotating engine clockwise (using a spanner on pulley nut) until No1 cylinder at TDC. I use a kebab stick down the cylinder and the marker on the dissy to check it is on compression stroke.






Now No 1 cylinder can be set. Turn adjuster by hand until zero lash. Or no movement from the rocker against the valve stem. Then using a screwdriver rotate the adjuster screw **two complete revolutions. Hold adjuster in place and lock the nut.





Now rotate crank clockwise (on the pulley) half a turn and repeat process for No 4. Repeat again for No 3 and No 2 cylinders.


**Question please. I have fitted new adjusters, the cylinder heads are reconditioned units, with new valves and springs etc. Two revolutions on the adjusters may well be too tight for running in. What settings on the valves are best?

Regards
Stuart

[maxstu]

Problem.... your advice please.
I took apart all the tappets and cleaned their internals. Then assembled with clean oil and all carefully bled and check for firmness. That was some weeks ago. But l didn't store them submerged in oil.
Today while setting the exhaust valves on No 2 cylinder the tappet is soft.....all the rest are nice and solid.....so do l leave it and let oil circulation on warm up refill it? Or do l remove rocker, take out push rod and cut out non adjuster tube and replace tappet with a properly bled one. And finally add an adjustable push rod tube.
Very annoying (mostly with myself) to ruin the good looking aesthetics of shiny original VW tubes with one crappy spring loaded one.

Or should l remove the cylinder head and pull out the dodgy tappet?

[ajsimmo]

Leave it, it'll be fine.

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[maxstu]

Leave it, it'll be fine.

Sent from my moto g(30) using Tapatalk

Phew! Thanks for the reassurance, Andrew.

What about valve setting for new adjusters and valves/springs. Still two revolutions after zero lash? I watched a video on Vanagain website, Ken Wilford head rebuild suggests just half a turn from zero lash?

Regards
Stuart

[ajsimmo]

Ideal compromise setting seems to be 1.5 turns. Half a turn isn't sufficient imho.

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[maxstu]

Thank you.

[Stesaw]

1.5 seems to be the concensus. Bible does say 2 full turns for new lifters / cam though, eh. I'm wondering if this cam i have needs a different adjustment setting with it apparently being higher lift? (But thats another story)
Glad to see you're nearly there stu.

Anoyher thing with lifters that have drained down if it doesnt sort itself out. Marco mansi said to me to wind the adjuster out to touching, go for 30 min drive then reset back to correct turns.

[maxstu]

1.5 seems to be the concensus. Bible does say 2 full turns for new lifters / cam though, eh. I'm wondering if this cam i have needs a different adjustment setting with it apparently being higher lift? (But thats another story)
Glad to see you're nearly there stu.

Anoyher thing with lifters that have drained down if it doesnt sort itself out. Marco mansi said to me to wind the adjuster out to touching, go for 30 min drive then reset back to correct turns.

Okay and thanks....

All manuals in my possession read; two complete revolutions from zero lash, or just touching.

AJSimmo & Marco Mansi; one and half revolutions from zero lash.

Ken Wilford of Vanagain; suggests half a revolution from zero lash when using new AMC heads and new valves. He claims using two revolutions causes poor starting by holding the valves out too far and is not needed when the heads/valves are devoid of any carbon deposits.

I have fitted reconditioned AMC heads, with new valves and springs. So maybe a compromising setting of one and a quarter revolutions from zero lash? Time to reset valves again.

Thanks to all.

[Stesaw]

Whatcha waiting for? Get it in the van

[Smiffo]

Go on Stuart!!