jobs to do when replacing a DG

[ambivert]

Replacing a DG with a new (2nd hand) one, been advised to check the clutch on the new one. Don't know what to look for. Got haynes manual, will that tell me everything I need to know?
PS is there anything else I should check/replace while engine is out?

[T25Convert]

Hi,

While its out I'd check clutch, clutch release arm, fit a new clutch release bearing, fit new spigot bearing and fit new oilite bush for starter.

I'd also check end float on the new engine, and check that the rear crank seal is not leaking, replacing it if it is - it'll only get worse. Also check the exhaust studs/holes for exhaust studs are in good nick, easier to drill and tap them when the engine is out.

I'd also check the engine mounts - the rubber bit can split off the metal bit.

You could also clean up the engine bay and paint and treat any rust - much easier with the engine out.

The Haynes manual (and the wiki on here) should see you good on all of this....

Cheers,

Alex

[itchyfeet]

Whs is a very good list of stuff to do^^^
I would also take off the metal water pipes behind the pulley and give the a good scrape out if there is a rusty pin hole better to find it now than later, if they are crusty buy stainless replacements.

Early or late engine, how much comes with new engine and how much is being swapped?

[ambivert]

Not sure exactly. Will post a photo when it arrives... should be tomorrow...

[itchyfeet]

Ok so what do you have now?
stick you van in your signature stops us having to guess

May not even have a clutch on it

whats wromg with the old engine

[ambivert]

1984 devon factory conversion.
1.9 petrol manual 4 speed DG.
Think its a moonraker ... but am not sure.
Think its got the early cooling system ... but am not sure.

Old engine is blown... consumes oil at about 1 pint per mile... illegally thick smoke out the back. only running on 3 cylinders, no compression in the other. Garage thinks the piston/ring has gone.

[Older 'n dust]

OK. I'm a woman and a bit thick... so just have to ask..... what's a DG??

[ermie571]

hiya!!

a DG is the engine code. Followed by 1.9 which is the engine size.

The DG is the most common 1.9 in the uk I reckon...the other one you will hear mentioned is the DF. DF bits do not fit the DG engine. The other engine code you will hear refered to is the mighty DJ! a whole 2.1!! normally this is a fuel injected engine...but lots of us have put a 2.1 on the carburettor of the 1.9 (ie we had 1.9 engines which died, expired, etc etc and we have changed them for a 2.1, as it is a direct replacement. The bus then goes a bit faster with a bit more power. Also good for LPG.

Other engines you may hear about are the MV or SS (both 2.1) the CU Aircooled 2ltr and the CT 1600 Aircooled, the CX a 166 diesel engine and the JX the turbo diesel 1600.

There....that's my knowledge pretty much exhausted lol!!

Em
xx

[T25Convert]

Oh, and on reflection put a new water pump on it too - its a pain to do when the engine is back in the van...

If your engine works well other than the oily smoke, consider switching over all ancillaries (assuming the new engine is not just long block anyway) - that will help with ant 'it doesn't start' problems that may come later!

Cheers,

Alex

[kevtherev]

OK. I'm a woman and a bit thick... so just have to ask..... what's a DG??

Silly
You're not thick.. just uninformed.
What has your gender got to do with anything?

[ghost123uk]

Old engine is blown... consumes oil at about 1 pint per mile... illegally thick smoke out the back. only running on 3 cylinders, no compression in the other. Garage thinks the piston/ring has gone.

Please can you find out and tell us which cylinder has the damage. There is a good reason for asking

If it is either of the left hand ones, then before re-fitting your "new" engine, carefully check that all / any of the thin coolant pipes are not blocked, especially at the "T" joins. There is one that runs around the top of the engine bay, another (rubber one) that feeds the left hand head with coolant and (depending on early or late) one (or more) around the thermostat. A blockage (quite common) in these pipes can cause overheating of the head and piston / head damage. You don't want to fit your new engine, only to repeat the damage to that one too. By the way, ask me how I know this (as they say) (Twas some years ago now thankfully).

This is what you can find (not mine, someone else’s pic )



~~~~~~~~~~~~~~~~~~~~~

Re early v late. I wonder if your new engine has the same water pump and thermostat as your existing engine ? (The early stat housing, metal and mounted on the water pump, is a sod to deal with and I think are rare as hens teeth to get if you damage it !!)

[ambivert]

Courier did not turn up today!
Should be tomorrow now...

I will make sure to compare both engines very closely and hopefully be able to use the best bits from each!