1987 DJ does not fit 1983 Cooling Pipes

[Robsey]

Just to confirm for Aidan, if I haven't already...

The correct part number is 025 129 607D.
There is allegedy one in the US of A for $154 plus astranomical postage.

Or I can get a used DJ housing for approx £40 and cut n shut it into my DF housing.

I did look at other vehicles such as 90s Vauxhalls, that used Bosch air flow meters with the same four bolt mounting footprint.
Mainly the 18SE, 20NE and C20NE engines, but the meter is mounted in the wrong direction.



Modifying the air-box mount for the DJ is an option.
The whole thing would have to move 3" (7.5cm) rearwards, roughly.

That would allow the water pipes to fit with the early elephant's trunk... just about.

More research required -

[T3luestar]

Could something like this be an option?

[Robsey]

Probably as a last resort...
Not a huge fan of K&N cone filters.
(Each to their own as they say.

I have a cheap DJ air box on it's way that I can hack to bits, without wrecking my complete casing here.

So plan is to fit early elephants trunk.
Fit early DF air box and see where everything lands.
Then mark out, cut n shut, and finally weld it all together with some abs welding rod and a hot air gun.



I'll try to keep the welds air-tight and tidy looking.

[Robsey]

Okay - I had a look of what room I had to play with.

The later elephants trunk fits the air-flow meter better.
The early one seems too small to fit over the casting.

A bit of rotating the trunk gives clearance from the water hoses.

Here is the rough air-flow meter position in relation to the early air box.



And the approximate position where I will need to cut and shut the air-flow meter mounting.



Just for info...
I can't believe that the late father in law allowed an air filter to get this dirty.



Yikes!!
Obviously very heavily oil vapour contaminated.
Must be the worst I have ever seen.

[icosahedron]

A word of warning before you start cutting: tilting the boot upwards raises the AFM. Verify that it doesn't interfere with the engine cover. I see that mine touches the insulation, which is not a problem, but in your case the AFM will be positioned further backwards and might foul the centre member.

[Robsey]

Thanks for the heads up on the cross bar.
I will look closer at that.

The van has continuously thrown up complications, so a few more seem to be par for the course.

I got the impression with my trunk / boot that it was already in it's highest position, and rotating it brought everything back an inch (2.5cm) or so, and possibly lowered the air-flow meter by approx. 1/8" or 3mm.

As they say... we shall see.

[Aidan]

Just spoke to Mark at Dream and Drive in Holland, he has both CV and GH/GW airboxes in stock, wants rid.......

[Robsey]

Ooh I am very interested for a GW / DH air box...

Don't suppose he has the cross engine pipe too.
No worries if not.
I have plans to fabricate my own if all else fails.

I will send him an email.
Thanks for the heads-up Aidan.

UPDATE - Email sent to
contact@dream-drive.nl

FURTHER UPDATES -
Mark replied very quickly with some very useful information.
Again, many thanks Aidan. Mark is an amazing knowledge resource.

He has advised that the early air boxes intended for 1.9 engines would slightly suffocate the 2.1 engine.
DJ air-box is a must...
Looks like a "move it back an inch or two" may be on the cards.