Date: Wed, 3 Oct 2012 18:35:20 -0700
Reply-To: Stacy Schneider <vwcrewman@GMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Stacy Schneider <vwcrewman@GMAIL.COM>
Subject: Re: Trouble getting WBX piston out
In-Reply-To: <BAY152-ds15744F81B787B43027F47CA0840@phx.gbl>
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When I did my 1.9 WBX 10 years ago ,I found that a Air
cooled engine case insert for the #3 cylinder worked great . This is the
insert that is in the case because you can not get to it with a dog house
cooler set up .
The insert fit perfectly in the center of the wrist pin and
inside the wrist pin hole of the piston . I then used a Long air cooled
case stud and a slide hammer or such to pull the pin .
Worked great for me as it was what I could round up in the
garage when doing the chore.
Stacy
On Wed, Oct 3, 2012 at 5:47 PM, Dennis Haynes <d23haynes57@hotmail.com>wrote:
> You need to get a little creative and maybe even have someone machine a
> sleeve for you. A 3/8" threaded rod and nut (9/16" hex) make a perfect
> puller set up. The nut will actually fit the pin and will even clear the
> snap ring. The trick is that the sleeve has to fit inside the water pump
> opening and the water pipe connection on the block and it should be notched
> to rest on the piston, supported by the recess for the pin. It should not
> rest on the side of the piston especially the ring groove. Resist the
> temptation to simply pull on the pin putting pressure against the case.
> This
> will put a side load on the connection rod which can damage the rod
> bearing.
> After this happens when the engine fails in the future we can blame it on
> the stretch bolts not the bad action dome earlier. The snap rings should be
> replaced. When putting the pistons back into the cylinders they should be
> inserted from the top. A ridge breaker should be used to cut the carbon
> ridge. Hone the cylinders lightly. They already have some wear and removing
> even a few thousandths will leave you an engine with piston slap. Note the
> pistons and the pins are directional. Keep track. Clean everything. The
> piston pins are only tough to remove due to carbon deposits. Solvent and
> keep working them in the pistons until they can slid through with just some
> hand pressure. I have learned to remove all the cylinders to clean tem
> really well, especially the top O-ring grove. I also use a bit of lapping
> compound and lap the cylinders into the heads to get the top of the
> cylinders really clean. This is the most important gasket sealing area. The
> top o-ring is just there to keep coolant out of that space. The top gasket
> is what holds back the compressive forces.
>
> For the head nuts they should be replaced or at least cleaned with a thread
> chaser. The threads need to be lubricated and the sealant only goes on the
> flange. Do NOT fill the cap nuts with anything as that will hydraulically
> prevent them from going all the way down. Apply the never-seize or
> lubricant
> of choice to the stud threads only. If you have stud that doesn't tighten
> up
> you should replace it.
>
> Dennis
>
>
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
> Jim Felder
> Sent: Wednesday, October 03, 2012 1:06 PM
> To: vanagon@GERRY.VANAGON.COM
> Subject: Trouble getting WBX piston out
>
> I managed to get the heads off of all the waterboxer's cylinders but one...
> and that one I had to stand on in the driveway and whang it with a hammer
> like it was a brake drum. Anyway it's out and now it needs to go back in. I
> have the wrist pin pulled out of the piston about 1/4 inch past the piston
> edge, so I've made a little progress, but now it seems that it does not
> want
> to move any more, at least with what I am moving it with. I have a bolt on
> my puller, about 3 pounds, and I put the head through and catch it on the
> far side of the wrist pin, working from the front of the engine.
>
> Does anyone know of a better way? A better choice of puller tools (I don't
> have any fancy expanding collets)? Would about an hour of propane on the
> piston crown loosen things up around the wrist pin?
>
> Got the heads back, want to get on with this project.
>
> Jim
>
--
1989 Swedish Tristar with Aluminum gates and Atiwe 16" Wheels.
Oldest son is an Eagle scout.
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