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Well deffo not DJ. According to my manual crown of piston to second ring on DJ is 9.2 mm.
Looks like DG then..ooooh those naughty boys in Essex. They even tampered with engine prefix number.



Good news is l have spare rings for a DG

More DG evidence...

This just came out of head for 1&2
Is it important?

Also this way under one of the head nuts..

Well it was going so well....
Then on the final step up to 7mm for retap exhaust and crack. Drill caught and snapped. Any suggestions??

Quiet here today Am l missing something? Wedding or a funeral perhaps?
Anyway, managed to remove broken drill tip and save the day. Will buy another 7.5mm tomorrow.



So did a bit of cleaning instead..

Gord knows what that metal bit is Stu! Could they have used a DJ case and changed the innards, although that said, have they haven’t charged for a 2.1 engine?!

My engine that my pal rebuilt was also from Elite and had some of that gunky crap in it as well:

viewtopic.php?t=163364

maxstu wrote: ↑28 Jul 2020, 15:41 Well it was going so well....
Then on the final step up to 7mm for retap exhaust and crack. Drill caught and snapped. Any suggestions??

Maybe you might get lucky with some needle/long nose pliers?

FWIW, those are DG pistons and you cannot team them up with a 76mm crank, because at TDC the crowns will pop out the top of the barrels!

Its a DG. If you want a 76mm crank, I have a few ripe for regrinding. Might have a set of good used DJ pistons under the bench, need to have a clear-out.

Sorry I was right, best to let you know before you start getting too far into things

Your best hope with the drill bit is long nose pliers or a thin screwdriver to try and wind it out. After that it starts to cost money with spark erosion.

I don't recognise the metal bit out of the head........ so you either have a big piece missing which you should be able to compare with the other head, or the last person to do the engine left something behind Maybe it's a tool for altering engine numbers.

Thanks for the support my friends

Needle nose pliers saved the day with redrill of exhaust stud. Managed to remove the tip of the broken drill. I will buy a decent bit tomorrow and drill out further. Then buy a reducer stud.

Thanks for the offer Ian. However this is a spare engine and lm happy to keep it 1.9DG. I have enough spares for it too, as my first two campers were DG's.

Im also using this engine to enhance my wasserboxer rebuilding knowledge. You can tell it is somewhat limited. But l now know the difference betwix a DJ and a DG piston. So hey! We all have to start somewhere. And lm really enjoying the experience too.

And a big thanks to Elite in Essex for producing another crappy "rebuild"

More cleaning tomorrow.
Kind regards
Stuart

No sweat. If I knew then what I know now, I would have listened to the advice on offer and gone straight to DJ spec on my first DG rebuild.

silverbullet wrote: ↑28 Jul 2020, 19:19 No sweat. If I knew then what I know now, I would have listened to the advice on offer and gone straight to DJ spec on my first DG rebuild.

Are you suggesting l should go DJ while engine is open?
However, lm not financially solvent to start throwing money to alter this engine at present.......and have just got my second Post Office rejection for part time work. God l wish they would indicate my failings! So still unemployed/unemployable .....so l have mostly all the major spares to rebuild the DG engine to hand. And time aplenty!

maxstu wrote: ↑28 Jul 2020, 12:12 Well deffo not DJ. According to my manual crown of piston to second ring on DJ is 9.2 mm.

Whats the significance of the VW punchmark BTW?

https://club8090.co.uk/forum/viewtopic.php?f=37&t=164888

Second post... nice pictures of DG pistons too

The stamp is I think because it has been rebuilt by VW at some point....... buy mine has no engine number so either mine was rebuilt with fresh cases (which have no number), or at some point the policy was to remove the engine number. Someone has been a bit naughty with the code haven't they

Are you just doing a top end on this, i.e not splitting the cases ?

The metal bit looks like part of a thermostat to me