1.9DG to 2.1DJ engine swap

[keynsham1]

I'm happy to do a full rebuild. The last engine I did was a Porsche 911sc 3 litre lump and frankly they are riddled with bad design details and early failure points making rebuilds interesting! Really I am after a project. I will probably spend a year over it so a full strip to Component level would be happening anyway!

Just another thought. The 1.9 and 2.1 are very similar but I assume I couldn't just swap liners and pistons? No-one has mentioned it so I am guessing there are more internal differences? I haven't looked into it yet.

[Stesaw]

The crank is what makes the 1.9 to 2.1 different from what I recall.. also 1.9s generally use non stretch bolts in the rods and 2.1s use stretch ones.
The 2.1 is really just a long stroke 1.9 with higher compression. 2.1MV has a lower compression due the the pistons being different as I understand it.
I wouldn't bother swapping the 1.9 pistons into the 2.1 as they are different dish/dimple, (whatever) depths so I'd assume that would mess with compression ratings and probably run like a*** if at all.. but other more experienced engine monkeys might advise otherwise.
You might be able to swap over the barrels if the 2.1 ones are shot but its worth measuring up the pistons and ring gaps with them if you are gonna try that, if so give them a light hone so new rings would bed in.

Compression wise on the 2.1 engine I think when I did a test on mine they were all around 150PSI, which is on the lower side, I think the range goes up to about 190.

[keynsham1]

Yes I just had a look. I think both are 94mm bore but the 2.1 has a longer stroke. VW parts catalogue shows same pistons and liners for both but a different crankshaft part number.

Probably safer to keep my existong 1.9 completer as there is nothing wrong with it and find a 2.1 to play with!!

[Stesaw]

It's worth noting that youll be throwing a fair bit of money at a ground up build. If the heads are OK then you're gonna save about £800 or so, but you'd be best to check valves and guides on the current heads.. I think my build came in just under 3k... and that was without heads. For the money I could have probably gone most of the way to a 1.8t or Subaru conversion.

[keynsham1]

I have gone off the idea after looking for parts availability online. No camshafts available, no std pistons and liners to be seen, etc, etc. 

[maxstu]

It's worth noting that youll be throwing a fair bit of money at a ground up build. If the heads are OK then you're gonna save about £800 or so, but you'd be best to check valves and guides on the current heads.. I think my build came in just under 3k... and that was without heads. For the money I could have probably gone most of the way to a 1.8t or Subaru conversion.

I reckon l spent around 1K. Yet, l was was lucky. Case studs, crank and cam were in excellent standard condition on my DJ2.1. (Perhaps auto's suffer less stress?) And l was offered two AMC rebuilt heads for a very reasonable price.

Thank you fellow club member.

One off the joys of rebuilding these units is balancing the pistons and conrods for a smooth running engine. I got it down to single digit grams.

Such a lovely engine.

[Mocki]

Not being funny, but you might be as well talking to Andrew at campershack
memberlist.php?mode=viewprofile&u=10006

[maxstu]

I have gone off the idea after looking for parts availability online. No camshafts available, no std pistons and liners to be seen, etc, etc. 

No, don't. We want an engine rebuild to umm and ahh over.
You will be impressed with a 2.1. Even running on a carb.
Presently, l have a DJ2.1 and a DG1.9 LPG. The tortoise and the hare race comes to mind. It is such a lovely engine.

[Stesaw]

It's worth noting that youll be throwing a fair bit of money at a ground up build. If the heads are OK then you're gonna save about £800 or so, but you'd be best to check valves and guides on the current heads.. I think my build came in just under 3k... and that was without heads. For the money I could have probably gone most of the way to a 1.8t or Subaru conversion.

I reckon l spent around 1K. Yet, l was was lucky. Case studs, crank and cam were in excellent standard condition on my DJ2.1. (Perhaps auto's suffer less stress?) And l was offered two AMC rebuilt heads for a very reasonable price.

Thank you fellow club member.

One off the joys of rebuilding these units is balancing the pistons and conrods for a smooth running engine. I got it down to single digit grams.

Such a lovely engine.

I probably just got unlucky with mine.. The helicoiled head studs still make me nervous if I boot it.