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advice needed in doing the heads in 89 water boxer

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mjwcookie Seriously Crusin Dubber

105 posts · joined Mar 2011 ·

#865945
hi all. all advice gratefully received.

I am doing the heads on my 89 caravelle 2.1 injected. and have a few questions.

1. the fuel lines to the injector rails are old, can i just replace them or do i have to buy special ones? do they have to be exactly same length as the old ones? can i flush out the rails as i have had a problem with water in fuel somehow.

2. is there a trick to separating the sleeves from the heads before they slip off the pistons? Do the sleeves have sealing rings around their bases on the block?

3. i think the water pump is original and done 210k. should i replace it?

4. as the heads loosened, water leaked into the block, as I could not open the drain plugs under the pushroods. Seazed up and i did not want to break or crack anything. how can i be sure to have it all (water) our when i go to refill with oil?

Thanks. That is it so far.

Mark Wilson
Mark Wilson
78 bay window, 82 bay Westy. T3 Caravelle GL 89 on the road.
Now in Victoria.

vw54 Administrator Always Waiting 4 Friday

16,723 posts · joined Aug 2002 ·

#865978
Talk to VVDS at Campsie info@vintageveedub.com.au
I read it on FACEBOOK so it must be true


http://forums.aussieveedubbers.com/viewtopic.php?tid=91278&page=1#pid848630


http://forums.aussieveedubbers.com/viewtopic.php?tid=63561&page=1#pid624099


http://forums.aussieveedubbers.com/viewtopic.php?tid=4832&page=1#pid452603


http://forums.aussieveedubbers.com/viewtopic.php?tid=60650&page=1#pid574409

grumble Son of Jim - Creator of Good

2,672 posts · joined Jun 2008 ·

#865992
mjwcookie wrote:hi all. all advice gratefully received.

I am doing the heads on my 89 caravelle 2.1 injected. and have a few questions.

1. the fuel lines to the injector rails are old, can i just replace them or do i have to buy special ones? do they have to be exactly same length as the old ones? can i flush out the rails as i have had a problem with water in fuel somehow.

2. is there a trick to separating the sleeves from the heads before they slip off the pistons? Do the sleeves have sealing rings around their bases on the block?

3. i think the water pump is original and done 210k. should i replace it?

4. as the heads loosened, water leaked into the block, as I could not open the drain plugs under the pushroods. Seazed up and i did not want to break or crack anything. how can i be sure to have it all (water) our when i go to refill with oil?

Thanks. That is it so far.

Mark Wilson
In answer to the question No1 I have a set of injection hoses and fittings for a 2.1 and 1 new injector. Contact by pm if interested
no2 yes the main trick is luck,as you release the heads try to pry the cylinder lose from the head ( not usually successful)
No3 Yes replace the pump to save you doing it shortly after putting the engine back together
No4 Drain the oil and leave it draining whilst rebuilding the engine.
Cheers and good luck Les

mjwcookie Seriously Crusin Dubber

105 posts · joined Mar 2011 ·

#866002
how do i replace the sleeves into the block over the rings. seems like not much room. I expect to have to rotate the crank to get the piston all the way out, then do one, then rotate again. etc. Do the sleeves have sealing rings at the block end?
Mark Wilson
78 bay window, 82 bay Westy. T3 Caravelle GL 89 on the road.
Now in Victoria.

mjwcookie Seriously Crusin Dubber

105 posts · joined Mar 2011 ·

#866260
If I had the money, I would even bother trying to fix it, just slot in a subi. Unfortunately that is not an option. so far.

thanks.

Mark
Mark Wilson
78 bay window, 82 bay Westy. T3 Caravelle GL 89 on the road.
Now in Victoria.