1.9 to 2.1 petrol engine upgrade

[chappaz1004]

Guys,

i'm Steve - hope you are all having a very merry xmas period ...

I have a 1989 VW T25 CARAVELLE 1.9 PETROL. It has done in excess of 140k miles with no service history, it will sit at 50-60 quite happily on the motorway and struggles with hills. I am looking to replace this with a new/reconditioned DJ 2.1 petrol engine or simply replacing or reconditioning the current engine, personally I think the 2.1 is surely the better option.

As I am a communications specialist and have no real experience playing around with engines, how simple would this job be, how long would it take, and what extra parts other than the engine will be needed?

Forgot to mention the van has a 5-speed gear box.

I have searched through the forum and the archives and have been unable to satisfy my thirst for this information.

Cheers

[big red bus]

1.9 carb engine to 2.1 carb or 2.1 injected?

[chappaz1004]

I was thinking more along the injected side, is there much difference - Carb vs Inj??

[big red bus]

depends what your after. standard factory 2.1 dj/ss were injected but some fit a 2.1 and to keep the install simpler, just fit the 1.9 carb and get it rejeted. if want injection, you need engine loom, ecu, fuel pump, change fuel tank, theres more but can you see why people stick with the carbs. I have had a 2.1 injected and it was good. thirsty but they all. If you can get hold of everything you need, its all just bolt on/off to change things and the loom is easy to install as it oly connects into the black box in the engine bay. Oh will need pump relay and ecu relay as well and idle control behind lamp o/s/r . Can give you a detailed list if you want

[ninja.turtle007]

I'll have the complete 2.1 setup available for sale in January.

[Ian Hulley]

No need to re-jet the 1.9DG Pierburg carb, plug and play on a 2.1DJ

Done by loads of us now with nothing but smiles to show for it

Ian

[chappaz1004]

Thanks for your replies guys,

I am after a relatively simple hassle free engine replacement, I have found (on-line) a garage that will fit a 2.1 DJ for about £1.6k ... thats not telling them they are removing a 1.9 and installing a 2.1 though. Is it really that simple as 'Plug and Play', if it is I am definitely considering this option but will be opting for a new/reconditioned engine purely for piece of mind. If it is a little more than 'plug and play' other than re-jetting the carbs what is advisable to change at the same time as changing the engine over - preventative maintenance etc??

Thanks again

[toomanytoys]

Where abouts in the world are you??

Several threads on this, with a bit of searching...

Swapping the engine isnt the issue, its all the cruddy bits attached to it... if the exhaust is rotten then thats a new one needed, any worn out bits and bobs add to the cost.. new water pump, thermostat, any items that really should be addressed to do it right.. New clutch etc...
The "on line garage" will want to charge more as the engine isnt the same too..
Going from carb to Fi isnt easy.. you need all of the Fi stuff and it needs to be in good condition and known working... A 2.1 will happily run on the carb and the extra torque makes all the difference..

If the current engine isnt throwing up any issues, then run it for a bit and save up for the engine swap.. Make sure its serviced and set up properly...
I am in te throws of biulding improved waterboxers... but they are not going to be ready yet...

[Ian Hulley]

Late systems (exhaust and cooling) 1.9DG carb swapped for late systems 2.1DJ carb takes a day or so.

Common sense jobs ... replace clutch, replace spigot bearing, replace engine mounts, replace fuel hoses, replace waterpump, check all coolant hoses & pipes, undo and check all fasteners on the replacement engine (particularly the exhaust if there is one on it and thermostat housing) general check round and tidy up the empty engine bay. There are others which slip my decrepid mind.

Ian