Hi all. New to the whole VW/Camper thing. Recently purchased one as my new project, moving away from Classic Mini's. I'm a mechanic by trade and have always prefered older vehicles to own, drive and work on. Having never owned anything with a boxer engine and knowing quite literally nothing about them I decided to buy a 1984 VW T25 Hi-Top... in kit form... It basically needs an engine and the whole interior replacing with the exterior being relatively solid and rust free.
However, the previous owner decided to remove/strip the engine to try and repair it, to find that it had shattered a piston at which point he decided to get rid.
I am currently replacing an engine in a T25 at my work, which is a 1.9DG, due to the oil pump failing and have noticed that my engine has a few significant differences which has led me to believe that the engine that has come with my Camper is actually a 2.1DJ engine.
The thermostat housing is completely different. Mine has a P/N which appears to be 025121171 and one of the the heads is stamped with the P/N of 025101375B, which when googled turn up as being a 2.1DJ engine.
So, after my long winded story I am after some technical advice.
Can anyone confirm what engine I have from the above part numbers?
And if it does turn out to be a 2.1, is it easy to fit a 1.9DG in its place? As I have been given the old engine from the T25 at work, which would be much easier to salvage than my engine.
Apologies for the long read, any information would be greatly appreciated.
Lee
Engine query
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ghost123uk
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Re: Engine query
Hiya Lee, welcome to Club 80-90 where you will find all you need to know (and lots that you don't 
)
It certainly looks like you have a 2.1 DJ engine, the two types are completely interchangeable. The DJ normally runs a relatively simple fuel injection system whereas the 1.9 DG runs a Peirburgh carb. However it is not at all uncommon for a DJ to have been retro fitted with an inlet and carb off a DG, esp if the original DG was replaced by a recon 2.1 as folks often do (Often via "Elite Engines") The 2.1 is slighly more prone to major internal failure, such as may have been the case with yours, throwing rods and thus damaging pistons. There is an earlier again 1.9 version with the code DF, these are less powerful and not so desirable, but again, the same layout and fully interchangeable.
There was a fairly major change to the ancillaries in around 1985 when the thermostat was changed from a metal one (very hard to get now) near the water pump to a plastic one at the front nearside of the engine. The earlier system had different cooling hoses around the engine (also hard to source). However it is quite easy to change all those bits to the later type. If yours is 84 it should be the earlier type of ancillaries.
)It certainly looks like you have a 2.1 DJ engine, the two types are completely interchangeable. The DJ normally runs a relatively simple fuel injection system whereas the 1.9 DG runs a Peirburgh carb. However it is not at all uncommon for a DJ to have been retro fitted with an inlet and carb off a DG, esp if the original DG was replaced by a recon 2.1 as folks often do (Often via "Elite Engines") The 2.1 is slighly more prone to major internal failure, such as may have been the case with yours, throwing rods and thus damaging pistons. There is an earlier again 1.9 version with the code DF, these are less powerful and not so desirable, but again, the same layout and fully interchangeable.
There was a fairly major change to the ancillaries in around 1985 when the thermostat was changed from a metal one (very hard to get now) near the water pump to a plastic one at the front nearside of the engine. The earlier system had different cooling hoses around the engine (also hard to source). However it is quite easy to change all those bits to the later type. If yours is 84 it should be the earlier type of ancillaries.
Got a new van, but it's a 165bhp T4 [shock horror] Accurate LPG Station map here
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lawnmowercrap
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Re: Engine query
That sounds more like it, the thermostat housing on the one at my work is a plastic one at the top left of the engine bay (when looking at it from the back) whereas mine is a metal one attatched to the body of the water pump itself.
Mine is fitted with a carb, which appears to be very basic in comparison to the one at my work (less electical connectors and alot smaller)
Thank you for that, its good to hear that the engines are easily interchangeable. Though from what you have told me, would I be best to hunt down an earlier 1.9DG so that the ancillaries are correct for my van? (Though the thermostat housing has a stud snapped in it
)
Or would I be best to hunt down a later 1.9DG and ask for the coolant pipes/stat housing to be supplied with the engine?
Apologies for all the questions, im a wasserboxer novice ha ha!
Thanks, Lee
Mine is fitted with a carb, which appears to be very basic in comparison to the one at my work (less electical connectors and alot smaller)
Thank you for that, its good to hear that the engines are easily interchangeable. Though from what you have told me, would I be best to hunt down an earlier 1.9DG so that the ancillaries are correct for my van? (Though the thermostat housing has a stud snapped in it
)Or would I be best to hunt down a later 1.9DG and ask for the coolant pipes/stat housing to be supplied with the engine?
Apologies for all the questions, im a wasserboxer novice ha ha!
Thanks, Lee
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ghost123uk
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Re: Engine query
lawnmowercrap wrote: Mine is fitted with a carb, which appears to be very basic in comparison to the one at my work (less electrical connectors and alot smaller)
Check that carb, it should be the same as the one at work. If it is a Webber don't get excited, the Webber replacement for the usual Pierburgh are not at all good, see more on this below.
lawnmowercrap wrote:Thank you for that, its good to hear that the engines are easily interchangeable. Though from what you have told me, would I be best to hunt down an earlier 1.9DG so that the ancillaries are correct for my van? (Though the thermostat housing has a stud snapped in it
Or would I be best to hunt down a later 1.9DG and ask for the coolant pipes/stat housing to be supplied with the engine?
Definitely look for a later DG motor with it's later water pump, stat and pipes, preferably with a carb ( re mention above )
However that might not be easy (though not impossible) so if you have to, get an earlier version (remember, engine is exactly the same inside) and put up with the earlier ancillaries, lots of folk on here have the earlier type and except for water pipe availability they cope. However, you will have to sort the stat housing out (carefully !!). Then you have exhausts to consider, rusty studs snapping off etc, take care there, it can end up in BIG tears if you get it wrong. PlusGas (NOT WD40 !!) and heat from a gas blow torch are your friends. btw, the early and late exhausts are also fully interchangeable, the early being cheaper and easier to fit, but a bit louder.
Got a new van, but it's a 165bhp T4 [shock horror] Accurate LPG Station map here
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kevtherev
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Re: Engine query
Different engine mount for later exhausts.
Make sure the pierburg is fitted to the 1.9 or it will not perform.
The electrical connections to the manifold heater choke heater and idle speed cut off solenoid are required.
As is a coolant supply to the manifold and carb under the pierburg.
The cooling system surrounding the engine must be one or the other it's impossible to mix the two. (early or late)
Make sure the pierburg is fitted to the 1.9 or it will not perform.
The electrical connections to the manifold heater choke heater and idle speed cut off solenoid are required.
As is a coolant supply to the manifold and carb under the pierburg.
The cooling system surrounding the engine must be one or the other it's impossible to mix the two. (early or late)
AGG 2.0L 8V. (Golf GTi MkIII)
Re: Engine query
my guess is 84 van came with a DF or DG engine code and you have the early single choke carb and early cooling system
the later DG and DJ(2.1) can be made to fit but you will need a couple of more things than the basic engine- coolant manifold & pipes
if however you have everything from your engine you can remove the later cooling system and fit your early one complete but this is not great in the long run as lots of parts are now obsolete if you need to replace them
few extra hoses on the 2.1 as its got an oil cooler.
later DG/DJ ran 228mm clutches , DF and some DG motors ran 215mm clutches
al the basic bits / dizzy / flywheel / manifold/alternator ect are a straight swap.
you cannot mix the cooling systems so you either need all early or all later
2.1 only originally came with fuel injection 1.9 came with carb in this country but other countries had fuel injection - carb setup fits directly on the injection models
the later DG and DJ(2.1) can be made to fit but you will need a couple of more things than the basic engine- coolant manifold & pipes
if however you have everything from your engine you can remove the later cooling system and fit your early one complete but this is not great in the long run as lots of parts are now obsolete if you need to replace them
few extra hoses on the 2.1 as its got an oil cooler.
later DG/DJ ran 228mm clutches , DF and some DG motors ran 215mm clutches
al the basic bits / dizzy / flywheel / manifold/alternator ect are a straight swap.
you cannot mix the cooling systems so you either need all early or all later
2.1 only originally came with fuel injection 1.9 came with carb in this country but other countries had fuel injection - carb setup fits directly on the injection models