Heads Off Due To Pressurised Coolant

Big lumps of metals and spanners. Including servicing and fluids.

Moderators: Moderators, User administrators

User avatar
maxstu
Posts: 1898
Joined: 07 Feb 2008, 01:05
80-90 Mem No: 3946
Location: Margate

Re: Heads Off Due To Pressurised Coolant

Post by maxstu »

Well deffo not DJ. According to my manual crown of piston to second ring on DJ is 9.2 mm.
Looks like DG then..ooooh those naughty boys in Essex. They even tampered with engine prefix number.Image

Image

Good news is l have spare rings for a DG :rollin
Maxstu
1989 DJ 2.1 Auto Leisuredrive rusty bucket.
"Blissfully happy in your presence".

User avatar
maxstu
Posts: 1898
Joined: 07 Feb 2008, 01:05
80-90 Mem No: 3946
Location: Margate

Re: Heads Off Due To Pressurised Coolant

Post by maxstu »

More DG evidence...

Image
Maxstu
1989 DJ 2.1 Auto Leisuredrive rusty bucket.
"Blissfully happy in your presence".

User avatar
maxstu
Posts: 1898
Joined: 07 Feb 2008, 01:05
80-90 Mem No: 3946
Location: Margate

Re: Heads Off Due To Pressurised Coolant

Post by maxstu »

This just came out of head for 1&2 :shock:
Is it important?Image

Also this way under one of the head nuts..
Image
Maxstu
1989 DJ 2.1 Auto Leisuredrive rusty bucket.
"Blissfully happy in your presence".

User avatar
maxstu
Posts: 1898
Joined: 07 Feb 2008, 01:05
80-90 Mem No: 3946
Location: Margate

Re: Heads Off Due To Pressurised Coolant

Post by maxstu »

Well it was going so well.... :roll:
Then on the final step up to 7mm for retap exhaust and crack. Drill caught and snapped. Any suggestions??
Image
Maxstu
1989 DJ 2.1 Auto Leisuredrive rusty bucket.
"Blissfully happy in your presence".

User avatar
maxstu
Posts: 1898
Joined: 07 Feb 2008, 01:05
80-90 Mem No: 3946
Location: Margate

Re: Heads Off Due To Pressurised Coolant

Post by maxstu »

Quiet here today :shock: Am l missing something? Wedding or a funeral perhaps?
Anyway, managed to remove broken drill tip and save the day. Will buy another 7.5mm tomorrow.

Image

So did a bit of cleaning instead..

Image
Maxstu
1989 DJ 2.1 Auto Leisuredrive rusty bucket.
"Blissfully happy in your presence".

User avatar
300CE
Posts: 2082
Joined: 16 Aug 2012, 13:05
80-90 Mem No: 12017
Location: Sidcup, Kent

Re: Heads Off Due To Pressurised Coolant

Post by 300CE »

Gord knows what that metal bit is Stu! Could they have used a DJ case and changed the innards, although that said, have they haven’t charged for a 2.1 engine?!

My engine that my pal rebuilt was also from Elite and had some of that gunky crap in it as well:

viewtopic.php?t=163364
'86 DG, Weber Carb

Stesaw
Posts: 248
Joined: 10 Aug 2019, 23:30
80-90 Mem No: 17004
Location: Coventry

Re: Heads Off Due To Pressurised Coolant

Post by Stesaw »

maxstu wrote:
28 Jul 2020, 15:41
Well it was going so well.... :roll:
Then on the final step up to 7mm for retap exhaust and crack. Drill caught and snapped. Any suggestions??
Image

Maybe you might get lucky with some needle/long nose pliers?
1985 LeisureDrive 1.9DG 5 Speed

User avatar
silverbullet
Trader
Posts: 13136
Joined: 08 Jun 2009, 09:51
80-90 Mem No: 6908
Location: Surrey Syncronaut #156
Contact:

Re: Heads Off Due To Pressurised Coolant

Post by silverbullet »

FWIW, those are DG pistons and you cannot team them up with a 76mm crank, because at TDC the crowns will pop out the top of the barrels!

Its a DG. If you want a 76mm crank, I have a few ripe for regrinding. Might have a set of good used DJ pistons under the bench, need to have a clear-out.
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

User avatar
937carrera
Posts: 3415
Joined: 05 Apr 2015, 19:29
80-90 Mem No: 16333
Location: N Yorks.

Re: Heads Off Due To Pressurised Coolant

Post by 937carrera »

Sorry I was right, best to let you know before you start getting too far into things :roll:

Your best hope with the drill bit is long nose pliers or a thin screwdriver to try and wind it out. After that it starts to cost money with spark erosion.

I don't recognise the metal bit out of the head........ so you either have a big piece missing which you should be able to compare with the other head, or the last person to do the engine left something behind :roll: Maybe it's a tool for altering engine numbers.
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

User avatar
maxstu
Posts: 1898
Joined: 07 Feb 2008, 01:05
80-90 Mem No: 3946
Location: Margate

Re: Heads Off Due To Pressurised Coolant

Post by maxstu »

Thanks for the support my friends :ok

Needle nose pliers saved the day with redrill of exhaust stud. Managed to remove the tip of the broken drill. I will buy a decent bit tomorrow and drill out further. Then buy a reducer stud.

Thanks for the offer Ian. However this is a spare engine and lm happy to keep it 1.9DG. I have enough spares for it too, as my first two campers were DG's.

Im also using this engine to enhance my wasserboxer rebuilding knowledge. You can tell it is somewhat limited. But l now know the difference betwix a DJ and a DG piston. :rofl So hey! We all have to start somewhere. And lm really enjoying the experience too.

And a big thanks to Elite in Essex for producing another crappy "rebuild" :ok

More cleaning tomorrow.
Kind regards
Stuart
Maxstu
1989 DJ 2.1 Auto Leisuredrive rusty bucket.
"Blissfully happy in your presence".

User avatar
silverbullet
Trader
Posts: 13136
Joined: 08 Jun 2009, 09:51
80-90 Mem No: 6908
Location: Surrey Syncronaut #156
Contact:

Re: Heads Off Due To Pressurised Coolant

Post by silverbullet »

No sweat. If I knew then what I know now, I would have listened to the advice on offer and gone straight to DJ spec on my first DG rebuild.
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

User avatar
maxstu
Posts: 1898
Joined: 07 Feb 2008, 01:05
80-90 Mem No: 3946
Location: Margate

Re: Heads Off Due To Pressurised Coolant

Post by maxstu »

silverbullet wrote:
28 Jul 2020, 19:19
No sweat. If I knew then what I know now, I would have listened to the advice on offer and gone straight to DJ spec on my first DG rebuild.

Are you suggesting l should go DJ while engine is open?
However, lm not financially solvent to start throwing money to alter this engine at present.......and have just got my second Post Office rejection for part time work. God l wish they would indicate my failings! So still unemployed/unemployable :D .....so l have mostly all the major spares to rebuild the DG engine to hand. And time aplenty!
Maxstu
1989 DJ 2.1 Auto Leisuredrive rusty bucket.
"Blissfully happy in your presence".

User avatar
maxstu
Posts: 1898
Joined: 07 Feb 2008, 01:05
80-90 Mem No: 3946
Location: Margate

Re: Heads Off Due To Pressurised Coolant

Post by maxstu »

maxstu wrote:
28 Jul 2020, 12:12
Well deffo not DJ. According to my manual crown of piston to second ring on DJ is 9.2 mm.
Image

Whats the significance of the VW punchmark BTW?
Maxstu
1989 DJ 2.1 Auto Leisuredrive rusty bucket.
"Blissfully happy in your presence".

User avatar
937carrera
Posts: 3415
Joined: 05 Apr 2015, 19:29
80-90 Mem No: 16333
Location: N Yorks.

Re: Heads Off Due To Pressurised Coolant

Post by 937carrera »

https://club8090.co.uk/forum/viewtopic.php?f=37&t=164888

Second post... nice pictures of DG pistons too

The stamp is I think because it has been rebuilt by VW at some point....... buy mine has no engine number so either mine was rebuilt with fresh cases (which have no number), or at some point the policy was to remove the engine number. Someone has been a bit naughty with the code haven't they

Are you just doing a top end on this, i.e not splitting the cases ?
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

User avatar
Cobra88
Posts: 767
Joined: 03 Apr 2018, 18:24
80-90 Mem No: 16481
Location: Ipswich

Re: Heads Off Due To Pressurised Coolant

Post by Cobra88 »

The metal bit looks like part of a thermostat to me
____________________________________________
84 CaravelleGL 1.9 DG WBX Bronze Beige Metallic auto

Post Reply