engine rebuild or replace 1.9dg

[itchyfeet]

DG is 10bar to 13bar , 8 bar minimum, 3 bar max variation.

10 bar is 145 psi
8 bar lower limit is 116 psi

[adrian1975]

So to summerize
Is it worth rebuilding the bottom end or is it all good
If it was yours what would you do
Cheers Adrian

[itchyfeet]

Oil pressure is OK ( 2bar @ 2000rpm 80 degrees oil temp is a minimum with 15w40 but OK) but as I said check your cam when barrels are out, if it's badly worn it's worth splitting the case and changing it because a worn cam will stop it breathing properly.

DG cam is 7.3mm lift inlet and 7mm exhaust, I measured a new VW one with a dial guage and mounted in a lathe on dead centres so pretty accurate


you could measure lift at the cam followers.

[123-jn]

Having done 3 of these engines now I would say that they are quite easy to get out and case separation is pretty easy so I would not go to all the trouble of new rings, valves etc without doing the bearings. It is unlikely that the crank is worn enough to need a regrind and a set of new mains and big ends is only about £70.00. While you are in there if you have stretch bolts treat it to a set of non stretch from heritage and use a tad of threadlock when you do them up. Also when you improve the compression you put more stress on an already worn bottom end so do the lot. My Dg went up to a good 170psi after a refresh, rings, valves etc. My DJ is now between 187 and 195 PSI.

Just don't drop any washers in the cylinders while you put it together. I wonder how I know?

[adrian1975]

Thanks for the replys, so far ive got the barrels and pistons out, no scoring ect, they are very clean ive checked checked con rod endfloat and within tolerance, heads are going in the manchune shop on Monday relapping, valve guides replaced if needed, I'm going to get them to hone the barrels aswell ready for new rings,

Couple of questions,

Where do I get the black and yellow sealant

Also ive got a core plug leaking next to dipstick hole at the front what size is it and where can I buy one

Thanks Adrian

[itchyfeet]

I always buy the elring kit, comes with everything you need.

Elring full gasket set part number 356.362 ( comes with Dirco S and yellow sealant) £100 ( two single cylinder head kits are not the same as one full kit)
https://www.brickwerks.co.uk/t3-parts/e ... plete.html" onclick="window.open(this.href);return false;


just gone down in price at Brickwerks, they were out of stock so I had to buy the last two sets at 100 quid each elsewhere

check here for core plug part number
http://www.realoem.me/Volkswagen/RDW/T2 ... 1/101/3010" onclick="window.open(this.href);return false;

I think you need this

https://www.vwheritage.com/shop/0431011 ... -2-x-16-5/" onclick="window.open(this.href);return false;


please can you report back with how much you paid for the machine shop work and exactly what was done, would be good to know what people are charging these days.

[adrian1975]

Right, sorry its been a while, I git both heads back 8x valve guides, 8x recut valves, 8x relapse valves, 1 x helicoil, 4x whined barrels, £160 including vat, i was happy with the price,
I snapped a head bolt on reinstallation I'm waiting for it to turn up hopfuly Friday, built one side up now just waiting, mat black case, silver ancillaries, will look good when done, if I can uplaod a pic when finished I will,

The head work was. Done by Elmsleigh engineering in benfleet, Essex ive never used them before but looks good, I wont know till its back in the van really

Cheers I'll keep you posted

[adrian1975]

Substitute
Got for git
Relapse for relapped
Whined for honed

Sorry fat fingers and stupid phone

[adrian1975]

Hi guys just need a quick answer ive been offered a 5 speed box ABN gearbox code any good or stick with the 4 speed I know nothing about ratios or what ratio my 4 speed box is Adrian

[Smiffo]

To answer the last question, we would need to know what the asking price is...

Personally, I haven't driven a 4sp so don't have any comparison.
The 5sp I have ( ABK ) has same drive ratios as the ABN as per link here and the only complaint I have is that first gear is a bit high geared:

http://www.rjes.com/html/gearbox_types.html" onclick="window.open(this.href);return false;

I would be considering more variables. i.e. Is there anything wrong with yours.? What condition is the new one in ( is it a known good box? )
What is your existing box type and is your final drive ratio different than the one offered?

Basically, you have to ask yourself why you want to change, how much the new box is , what condition it's in and whether it is going to hinder funds / timescales etc on your engine rebuild already ongoing.

If it were me, I wouldn't bother, but only you can answer those questions for your own situation.

Lastly, if you decide to do it and want to make it pukka, you would be best doing the gear linkage bushes and changing the linkage setup to the 5sp variant too.
( I had 4sp set up on my 5sp box, and it was pants as you could't `feel` where the gears were, which meant Endless crunching until you learn the knack to find them... )

The only bit that would motivate me to do it would be if my existing box was on the way out anyway....

[multisi]

Hi guys just need a quick answer ive been offered a 5 speed box ABN gearbox code any good or stick with the 4 speed I know nothing about ratios or what ratio my 4 speed box is Adrian

Stick with your 4 speed, easier to use and cheaper if it needs to be rebuilt in the future.

[adrian1975]

Cheers for all your replies, the gearbox and engine was 220 for both early engine with headgasket gone and the gearbox, seemed cheap enough but I think ill leave it for now thanks anyway

[keynsham1]

Maybe a bit late now, but have you considered using an engine restoring additive such as Ametech Engine Restorer recommended by Quentin Willson? Please don't get me wrong here, as I don't really believe in any of these products, but if you are going to strip the engine anyway then surely it is worth a try....I guess it can't do any more harm? Any comments and any experience of these types of additive would be interesting!!