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Mon Jan 17, 2011 10:24 am

Yes, a misprint. Here is a picture of the micrometer set to 0.1111 inch. ( Correct me if I am wrong ). Each complete turn is 0.025 inch.

Thank you phych and 10c. I have learned a lot.

Mon Jan 17, 2011 10:47 am

Right, each full turn is .025".

It can take awhile to get the hang of reading the scale, so keep the instructions around and use it a lot so it becomes second nature.

Check it against the standard supplied, and adjust the witness mark with the little pin wrench provided so it's at zero, then check that occasionally, always with mic and standard at same temp.

Mon Jan 17, 2011 11:07 am

I got a nice set up to 6" from Enco on sale for a very reasonable price. I believe they were $80 or so if memory serves. Worth checking or getting on their mailing list.

Tue Jan 18, 2011 10:27 am

Time for a quick question. I'm stalled for a little bit simply due to my otherwise busy life.

I was looking in the Bentley, I believe p. 13-37. It shows an o-ring and a felt ring associated with the flywheel. I don't remember taking either of these off when I disassembled the motor (the downside of taking a long time between disassembly and reassembly).

Where the heck do these go?

It looks like there's a really small groove inside the flywheel where it slides on the crank. Not room for anything in there but the thinnest of o-rings. Is that where it goes. I still haven't opened my nifty, vacuum packed gasket set to see if there is a really skinny little o-ring in there.

Tue Jan 18, 2011 4:29 pm

There is a little o-ring that goes in the groove on the flywheel and the felt washer protects the pilot bearing. You got a better main seal (fw side) like a Sabo, right?

Wed Jan 19, 2011 8:28 am

I rebuilding a 2.1 with manual trans.

I watched Boston Bob's video, and he says to use a 10mm seal with the manual trans and a 12mm seal with an automatic trans.

The OEM one I pulled out is 10mm

The Sabo I have (and I think it is the only one they make) is 12mm. I am now leary of using my 12mm Sabo seal.

What say the masses? Is it ok to use 12mm seal with a manual trans?

Mon Feb 21, 2011 3:21 pm

Cool thread guys, I have documented the tear down on my 2.1 over on the club 80-90 forum in the UK - unfortunately mine is beyond economic repair though :(

Parts prices for these engines are crazy, i also run a '66 Mustang and I can get parts for that cheaper in the UK than I can get parts for the WBX - bizarre given one is made in Europe and the other over there! :shock:

Just bought a used 2.1 which is in good condition but has a water leak - pulled the heads and the rubber seal around the head is totally shot but pistons and liners look really good (also performed well on leak down test) so hopefully will be a solid engine.

Doesn't look like it has ever been opened up before.

A quick question - any tips for seperating the liners from the head, they are stuck solid. Used a rubber mallet to try and tap them loose but no joy.

Cheers,

MM

Wed Mar 09, 2011 6:46 am

I kinda got busy and never did finish this thread up. I find that working for a living gets me the money to do the things I want to do but denies me the time to do those things. Life's conundrum.

So this whole project ended up taking me a little over two months to complete. And it wasn't that big of a project. In reality I only replaced the bearings. Pistons, liners, rings, crank, cam, heads all had less the 50K on them and were in great shape so I just cleaned everything up and put it all back together again. I learned a bit about tolerances on these motors (thanks a million tencent and others) and got familiar with some of the nuances (each motor has a few things that are unique to their design even though the basic principles are all the same).

So, it's a beautiful thing;

I promised somebody early in this thread that I'd show a little detail of the oil cooler installation on this van. Here's the adapter plate;

Note that on the 1.9L engine this particular orientation is the only way I could make it work. It's the only clear path for the hoses to get out which leads to the following condition;

Notice how close they come to the exhaust header. This is what caused this whole teardown. The hose shifted and got right up ON the header and burned a hole in the hose, consequently dumping all of my oil in just a couple of minutes. The hoses are now well secured and I can get maybe two fingers between them and the header.

Anyway, I've now got a couple of hundred miles on it. It fired right up on the first crank, idles well and runs well. So far, no leaks.

I have noticed on the first tank that my mileage is waaaay off. I only got 12 mpg on the first tank and usually I get around 17 in town. I've got something buggered up with the FI system so I'm gonna run through the Bentley diagnostics and see where I end up. If it gets to be another 'project' I'll start another thread (if a search doesn't turn anything useful up).

Thanks again for all the support and info. This one has been fun.

Thu Mar 10, 2011 9:55 am

Congrats on completing the rebuild and getting your rig back on the road. And thanks for sharing your pics and info. Hope you get out on the road lots with your Westy.