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Jockomo
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Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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 Posted: Thu Mar 22, 2012 11:13 am Post subject: The Dharma Bus |
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Finally starting a project thread for my bus.
I know, such a cliche name, but honestly it was named this at least 10 years before "Lost" came out. Our band was named Dharma and the bus carried our gear. Needless to say we all flipped when we saw the bus on Lost.
Anyway, it's a 75 Westy. It was originally from Germany and the owners got it over to the states somehow. From what I understand the bus caught on fire on I-10 just outside of our town. It sat in a junkyard for 10 years before the PO got it and put a too small engine in it (don't remember exactly what)
Sometime around 98 I put a 2L 78 engine in from GEX and scrounged parts from another engine I pulled from a junkyard. Did some great trips in it back then and then sometime around 03 I decided to drop the insurance because I had another daily driver.
So now the daily driver has given up the ghost and it's time to bring the bus back to life.
Below are some pics
I've had a problem lately, that I think is a leak in the clutch area. I found alot of what looked like oil or transmission fluid in there and I think that was making the clutch slip. I have a new seal for the trans and a one for the engine otw.
So I have the engine out and on a stand.
And I'm wondering, is it ok to rotate the engine and leave it in whatever position I need it in? I hope so, because it's been sitting like that. (the oil has been drained)
I took the heads off to check out the condition of the valves.
Here is what I found:
First, I see this doesn't look quite right. Shouldn't I have a spring between there instead of a spacer and those older spring washers?
Anyway here is my head:
And one of the pistons, other is about the same.
My plan at this point is to remove the valves and get them clean to get a better look at them and clean up the rest of the head.
I'd also like to clean the piston top, from what I understand if I can keep the sleeve seated in the engine body and move the piston to the end of the sleeve and clean it off. Maybe this is not even needed, I'm not sure.
I'm already into a bit of unknown territory at this point and could use some advice as to how far I should take this inspection and cleanup.
Also the best way to clean the valves/etc.
I've got a new can of berryman carb cleaner, I plan to do that for about an hour for each part, then rinse with water and spray with wd-40 to keep rust free till reinstallation. Is this ok, any problems with mixing the WD-40 with the motor oil once it's installed?
Thanks
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'75 Westy with '78 2.0L engine. |
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curtis4085
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Jockomo
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Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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| Posted: Thu Mar 22, 2012 8:24 pm Post subject: |
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I've got the head much cleaner. But I'm a bit wary about pulling the valves.
Having never done it before. I have an overhead valve compressor but I'm concerned that I'll screw something up. Should I be?
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'75 Westy with '78 2.0L engine. |
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RatCamper
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| Posted: Fri Mar 23, 2012 2:30 am Post subject: |
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| Jockomo wrote: | I've got the head much cleaner. But I'm a bit wary about pulling the valves.
Having never done it before. I have an overhead valve compressor but I'm concerned that I'll screw something up. Should I be?
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So long as you have clean containers for everything, and make absolutely sure that nothing can get mixed up it should be fine. Last lot I pulled apart I had a whole pile of baggies which I wrote references on to the associated head, and wrote on the head with a paint pen. Be especially careful not to lose the valve collets. A magnetic tool can be handy for extracting them / putting them back as well. I have a type 4 bench tool and a generic screw style OHV valve tool and have pulled apart VW heads with both. It is seriously worth doing. I ruled out a few "good" heads because when I took out the valves the seats dropped out.
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Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002. |
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Jockomo
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Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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| Posted: Fri Mar 23, 2012 8:11 am Post subject: |
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Got one out. I was using the OEM Brand overhead valve spring compressor on loan from AutoZone. It sucks, at least for this. The way the tool fits the over the spring retainer doesn't work for these valves.
I had previously picked one up from Harbor Freight, and was going to return it since I hadn't opened it yet. But it happens to work great.
You can see how they compare, OEM on the left and HB brand "Pittsburg" on the right.
The HB also is built to fit the springs better with offset arms, plus they're spring loaded.
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Jockomo
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Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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| Posted: Fri Mar 23, 2012 12:47 pm Post subject: |
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Just found a bonus pair of exhaust manafold gaskets installed. Explains why they never fit right.
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chabanais
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Joined: July 27, 2002
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| Posted: Fri Mar 23, 2012 12:54 pm Post subject: |
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Is your lump still based on the GEX case?
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"I spud therefore I yam."
| Collie wrote: | | The silver socket is sacred and must not be disturbed |
| Serpent7 wrote: | | Keeping in-line with what VW originally had in mind; keeping the bus as close to OEM as possible with a few little changes to give it a "not forgotten look" but still maintaining the charm that made them what they are today. |
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Jockomo
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Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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| Posted: Fri Mar 23, 2012 1:42 pm Post subject: |
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| chabanais wrote: | | Is your lump still based on the GEX case? |
Not sure what you mean by lump, but I think yea, I'm still running the GEX case and heads. I noticed I was missing a washer on my rocker arms. Looking forward to seeing what other "surprises" they have in store for me!
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chabanais
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Joined: July 27, 2002
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Location: West of the Mississippi River.
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| Posted: Fri Mar 23, 2012 2:01 pm Post subject: |
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"Lump" is slang for engine, motor is slang for car.
GEX doesn't have the best reputation around these parts, hope yours is the exception.
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"I spud therefore I yam."
| Collie wrote: | | The silver socket is sacred and must not be disturbed |
| Serpent7 wrote: | | Keeping in-line with what VW originally had in mind; keeping the bus as close to OEM as possible with a few little changes to give it a "not forgotten look" but still maintaining the charm that made them what they are today. |
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Jockomo
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Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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| Posted: Fri Mar 23, 2012 6:18 pm Post subject: |
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Ah, thought that might be the case.
Anyway, the first head is all back together. I pulled all the valves and cleaned them and the seats up. I think they look ok. No damage anyway from what I could tell.
I did find that I was missing a flat washer for the #2 rocker arm. Anyone happen to have one of those laying around? I'd gladly pay for it.
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chabanais
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Joined: July 27, 2002
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Location: West of the Mississippi River.
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| Posted: Fri Mar 23, 2012 9:45 pm Post subject: |
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Might want to ask your question here:
http://www.thesamba.com/vw/forum/viewforum.php?f=12
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"I spud therefore I yam."
| Collie wrote: | | The silver socket is sacred and must not be disturbed |
| Serpent7 wrote: | | Keeping in-line with what VW originally had in mind; keeping the bus as close to OEM as possible with a few little changes to give it a "not forgotten look" but still maintaining the charm that made them what they are today. |
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Jockomo
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Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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| Posted: Tue Mar 27, 2012 8:58 am Post subject: |
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I picked up an engine gasket kit from Victor Reinz.
There is no list of what parts are in the kit, but it is sorted into a few different bags.
I'm trying to figure out what some of these are for.
Specifically it came with 3 sets of 4 gaskets that are all about the size of the cylinders. Two of them are for the cylinders i'm sure, and I can match those to the old gaskets pretty easy.
But there is the third set, they are very thin, like 1/4 the thickness of the cylinder gaskets but very slightly larger in diameter.. Almost more like shims.
Are these shims for the flywheel?
It's part number 17-00121-01 I see another samba thread with that number, but no answer. Any clues?
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'75 Westy with '78 2.0L engine. |
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Jockomo
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Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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Jockomo
Samba Member
Joined: October 11, 2006
Posts: 138
Location: Lafayette, LA
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| Posted: Thu Jul 19, 2012 11:01 am Post subject: |
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Very pleased to say that my bus is now running again.
Huge thanks to the fine folks here!
replaced:
all the shift couplings
CVs,
Transmission gaskets+ the little ball that the hockey stick fits into
Rear final drive seals
main drive seal
alternator wiring harness
main wiring harness
new pertronix svda and coil
rebuilt my weber progressive, with new jetting
clutch and pressure plate,
and more...
The make it go stage is done, now to make it stop 
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