Replacement DG petrol engine

[AdamW]

my dg engine overheated in the summer. Replacement dg engines are expensive. I have been told that a golf/passat engine will go straight in and be more reliable. Is this an easy swap or will I need to modify anything?

[Ian Hulley]

Welcome to the forum, please note the alternative engines forum https://club8090.co.uk/forum/viewforum.php?f=12 where lies the answers to yours and many, many more of the problems of the universe no-doubt

Ian

[shirelets]

Seems like you may be another Cumbrian? I'm rebuilding my DG after head studs corroded and water leaked, but all the internals are in very good condition. So probably can't help you except I'm learning about gaskets, seals, etc on this complicated engine, which you maybe already know about. What you will find is parts prices are astronomical and if you tot them up are likely to come to more than a 'recon' unit. Various threads on how much can be done to a recon for the price they are sold for. For parts, Nigel Howe at VW Heritage is superb and knows his stuff. If your engine has original bits in, all will have an original VW part number which will help on identifying journal sizes etc. Good luck and deep pockets!

[shirelets]

Oops sorry - inadvertently replied to the wrong post so ignore previous please!

[ghost123uk]

my dg engine overheated in the summer. Replacement dg engines are expensive. I have been told that a golf/passat engine will go straight in and be more reliable. Is this an easy swap or will I need to modify anything?

Hi Adam

No it is not a simple swap, you need a cross member of a Diesel T25 plus a bellhousing and a few other bits such as exhaust (obviously). Plus the carbed ones will not work 'out of the box' because of the engines 'lean' in our vans, though the GTi versions can be made to fit with the above parts.

To be honest, and I was considering this 'swap' a couple of years ago, I would just bite the bullet and go for an Elite VW recon unit at around £1000 including fitting. Or look for a good used one on here (there was one in our For Sale section a couple of days ago for £500 iirc) The good thing about buying one off here instead of Ebay is we tend to be honest folk and you are much less likely to buy a dog !

Mind you, if you can find a Diesel van in the breakers as a donor for engine mount cross beam, exhaust and bell housing etc, the Golf / Passat engine is a good reliable unit that is easy to get spares or replacements for.

[AdamW]

Thanks for the replies. I now have the DG engine out and on my garage floor. I am thinking about rebuilding it, but don't know much about engines. The deal from Elite VW is the best I seen for reconditioned engines. I live in Cornwall and finding a local 2nd hand engine in good condition would be good option. I am also concerned about the fuel economy which is one of the reasons I thought about trying to fit a diesel.
Any other suggestions welcome.
Adam

[kevtherev]

Another forum here is alternative fuels.
most flat four owners either take it on the chin or convert to LPG. which is half the price of petrol

[Ian Hulley]

but don't know much about engines.

I am also concerned about the fuel economy

With the greatest of respect it sounds like you've bought the wrong van mate. See here ... https://club8090.co.uk/forum/viewtopic.php?f=18&t=96792

Ian

[kevtherev]

my dg engine overheated in the summer. ?

So what damage was caused?

[AdamW]

The engine got hot enough for some of the wires on top to start melting.
The compression is low. I am told that the main bearing seem ok. One of the spark plugs has chewed up the thread.
I've started to take off the manifold and loosen 6 out of the 8 nuts/ bolts. One bolt has sheared off. The last bolt I can't get to very easily. This is at the back left hand side, bottom bolt. My 13mm spanner is a bit loose on it. Most of them undid with a 1/2'' ring spanner, but it won't go on to this one as the manifold is so close to the bolt. I'll get there in the end.
I take your point, Ian, but after spending my cash buying the van I want to get it back running.
Adam

[mm289]

Manifold nuts are a pig, especially the 2 you can't get a ring spanner too. Use a small sharp chisel and gently tap with hammer on the edge of one of the flats. Nut will start moving and then you can use a spanner on it - presume you have already soaked the nuts in penetrating fluid (PlusGas or similar)?

If it got hot enough to melt wires I would think it is well cooked, I would be doing a full teardown and measuring/inspecting bores, pistons, valves and bearings - you have been told the main bearing seem ok? (there are 4 BTW) - on what basis are they judged to be OK - really difficult to tell without a teardown.

Rebuilding a WBX isn't rocket science but it isn't as easy as say an Aircooled or a simple 4 cylinder Vauxhall lump. Lots of threads in this section if you want to see what one looks like and the work involved including a couple of mine https://club8090.co.uk/forum/viewtopic.php?f=37&t=80287 https://club8090.co.uk/forum/viewtopic.php?f=37&t=80287

If you aren't confident you know what you are doing i would be suggesting sourcing a replacement engine, either a "known good one"(upto£500), exchange(upto £1100) or remanufactured(upto £2000) but investigate these options properly and know the differences between them, see this thread from Fluzzenpuple for a similar conversation https://club8090.co.uk/forum/viewtopic.php?f=37&t=97076 - or convert as per your original idea, but a fair bit of work there as well

If many more of you West Country boys blow your engines I think I might relocate and set up a business rebuilding and installing engines - surf, sand, sun (?) and T25's what more could you want

Cheers,

MM

[kevtherev]

The engine got hot enough for some of the wires on top to start melting.
The compression is low. I am told that the main bearing seem ok. One of the spark plugs has chewed up the thread.
I've started to take off the manifold and loosen 6 out of the 8 nuts/ bolts. One bolt has sheared off. The last bolt I can't get to very easily. This is at the back left hand side, bottom bolt. My 13mm spanner is a bit loose on it. Most of them undid with a 1/2'' ring spanner, but it won't go on to this one as the manifold is so close to the bolt. I'll get there in the end.
I take your point, Ian, but after spending my cash buying the van I want to get it back running.
Adam

Is the exhaust in good shape or can it be cut free?
Am I right in thinking the engine is out?