New Amateur Engine Rebuild Featuring a DJ2.1

[maxstu]

This rebuild thread is (temporarily) on hold while l decide the best way forward with this DJ engine. Besides, l had the DJ crank reground to us .5mm and now Brickwerks are out of stock of that appropriate bearing.

So l have decided to turn to rebuilding an early DG1.9 l have in parts in garage. No point in having No2 DG Autosleeper camper sitting idle with a blown engine.

Perogative now is get that running so l can put up for sale my No1 DJ2.1 Leisuredrive camper to raise some sorely needed funds.

I'll be back...

[Simon Baxter]

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?

Glyco Logo.

 

[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?

Glyco Logo.

 

Thanks very much!

[maxstu]

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

Now, that is a big concern!

Today l started cleaning the cases and blowing out oil gallery with compressed air. A minute bit more "glove" debris popped out of here.




So l pushed a very thin but long screwdriver into here and here, and can feel sponginess of debris.



How the hell am l going to rid oil gallery of this debris?

How is the oil gallery connected? I can now push air or liquid between the blue oilways. But nothing moves between the other two in red?



Regards,
Stuart

[cobblers]

That's really strange. I wonder if someone had the oil pump off and blocked a hole with something "for a while".
Is the ribbed edge of the rubber "rolled" like a glove or just thicker, like the outside rim of an accelerator pump diaphragm?

We've got a high pressure parts washer machine in the workshop that would make light work of that - we use the pressure to blast out debris from the channels in hydraulic valve blocks and it works fantastically.

I'm not familiar with the exact layout of the oilways on a WBX, but I wonder if just getting a domestic pressure washer with a tight nozzle aimed in those holes would clear them?
Failing that, a bike brake inner cable in a drill will "snake" it's way through a surprisingly tight labyrinth, but the risk of it snapping off and leaving some debris in there is quite high.

[maxstu]

That's really strange. I wonder if someone had the oil pump off and blocked a hole with something "for a while".
Is the ribbed edge of the rubber "rolled" like a glove or just thicker, like the outside rim of an accelerator pump diaphragm?

We've got a high pressure parts washer machine in the workshop that would make light work of that - we use the pressure to blast out debris from the channels in hydraulic valve blocks and it works fantastically.

I'm not familiar with the exact layout of the oilways on a WBX, but I wonder if just getting a domestic pressure washer with a tight nozzle aimed in those holes would clear them?
Failing that, a bike brake inner cable in a drill will "snake" it's way through a surprisingly tight labyrinth, but the risk of it snapping off and leaving some debris in there is quite high.

Thanks for the ideas.

Rubber glove or silicone
Trying this method at the moment. Whatever it is? There is a lot of it. You can see debris 25mm along threads




Entering via .9bar oil switch hole with home made tool

[maxstu]

Debris behind this oilway plug, flywheel end. Thinking about drilling it out

[maxstu]

Getting bits out now...

[maxstu]

More bits.

[Stesaw]

Blimey that looks like it will be fun stu...
Perhaps an air line to blow the crap out?

[maxstu]

Blimey that looks like it will be fun stu...
Perhaps an air line to blow the crap out?

Firing away as l type. Lost the fine nozzle gun , though!

[cobblers]

Strewth! I really want to know what's happened here!

I see a couple of helicoils, so it looks as though it's definitely been stripped before.

[maxstu]

We are good to continue.
Here are the bits l removed from oil gallery.
I'm not guessing what it is or how it got inside. But it's out now. So continuing with rebuild.



To give some perspective of their sizes, 0.9 bar switch case bolt in photo too.

Headlamp wire connector cover comes to mind?



Sacrificed my tyre inflator hose to make a thin nozzle air line.




Onwards we go!

Regards
Stuart

[cobblers]

I reckon it's a rubber sleeve that goes over the connector onto the pressure sensor

[cobblers]