DJ2.1 Rebuild

[silverbullet]

Stop overthinking it!

Clean, dry, seal threads. End of problem.

[Stesaw]

Maybe for ease you could swap the head from the 1.9... just a thought

[ajsimmo]

Stop overthinking it!

Clean, dry, seal threads. End of problem.

This. ^

I certainly wouldn't be replacing the head just for that. Not really that much of a problem. I'd maybe tap the thread a bit deeper, seal that stud in there thoroughly with loctite, wound down nice and tight, job done. The m8 studs in the case for other coolant flanges are open at the back to pressurised coolant, and they don't leak.

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[mrhutch]

Stop overthinking it!

Clean, dry, seal threads. End of problem.

THIS!!!!

thats all that needs doing mate.  

[maxstu]

Yes. I know l am. But when you are touring with a neurotic ("it's not going to breakdown, is it?", every 15 mins) girlfriend and three dogs, and towing a small pop up caravan, l'm slightly bibs and brace nowadays.

I still have weimarbus's idea to to fall back on, and l think is more robust solution. Let me get the camper running
.
Have Loctite and new 8mm 1.25 tap.

I going in!

[cobblers]

A separate bung would just be sealed in the same as the stud anyway, the only advantage is that your fix won't accidentally unscrew when the next guy takes the manifold off one day.
Balls to the next guy! just send it in with some good thread seal.

[maxstu]

Tapped it to 28mm. Cleaned hole of swarf with neat alcohol and cotton buds. Dried out with a hot air gun.
Clean stud in neat alcohol. Dried. Cleaned my hand in neat alcohol, too. Dried both on a clean towel.
Applied a big dollop of Loctite 577 and screwed it in.

And the wait begin.....

[maxstu]

Maybe for ease you could swap the head from the 1.9... just a thought

Noooooooooooo!

[Stesaw]

Maybe for ease you could swap the head from the 1.9... just a thought

Noooooooooooo!

What, you had your fill of building?

[maxstu]

Added coolant yesterday afternoon. Slightly pressurised the system and left it overnight.
All good this morning. So many thanks to all.

Next problem. Added oil (primed oil filter too) and turned over engine using three ten second bursts with coil lead earthed to engine block and fuel injection system wiring disconnected.

Oil light on dash remains lit.

First l checked the the oil switch relocator. No oil getting to top of pipe. Another three ten second turn on the starter. No change.

So l primed the relocator pipe with from the top. Screwed on the 0-5 bar pressure sender and connected oil switch wire. Still no joy.








Removed a rocker cover. Maxine turned over engine and oil galore came splashing out.
Took out oil relocator pipe and returned to normal blue switch between pushrod tubes.
Turned over engine and still got red light on dash.

Im baffled?????

[tobydog]

Switch?

[maxstu]

Switch?

Tried a pressure sender and new switch.
Just checking wiring going to both low and high pressure oil switch.

[maxstu]

Both oil switches changed. Still light on dash illuminated. Wiring check to black box. I even earthed out high pressure switch wiring to eliminate it from the issues.
I fitted oil pump using assembly lube. Should l have primed with oil?
Oil relief valve, perhaps?

[cobblers]

How fast is it turning over? Maybe take the spark plugs out to get cranking faster and see if it'll start picking up properly, then obviously put them back in and re-test it once primed.

I've tested/primed WBX oil pressure with the engine on the floor by taking the plugs out and spinning the crank over with a drill. Not sure if this would work with a freshly built engine that's a bit tighter.

[maxstu]

Thanks for the idea, Cobblers. The battery is not holding up too well, now. Ive ordered a fresh one for delivery tomorrow.

As l am using new valves and adjuster studs in reconditioned heads l decided to set the lash at 1 plus a quarter turn from touching. A precaution against using new valve and rockers together with original pushrod and followers, l read.

Perhaps the engine is not getting enough valve left to inject fuel. Plugs are dry.

Enough for today.