Club 80-90 Forums

i have a 19 dg engine and would like a bigger 2.1 dj so what do i need
a complete engine with ecu or run on 1986 dg carb
injection different fuel tank with larger swirl pot?? or run on carb
any help

Hi Simon

I'm told it's a simple swap of just the basic engine - all your existing ancillaries should just bolt on to the 2.1. I'm attempting the same thing - I have a 1.9DG with the early cooling system, and I've bought a scrap 2.1MV to rebuild. I'm planning to use the carb, distributor, alternator, fuel pump etc etc from my DG, and even my existing early cooling system. I've had some useful advice in my thread about this.

hi chris would like a bit more power for hills and over taking so my carb on on the engine and thats it ?? dont need petrol tank cause its getting to be lots more money?? cheer mate

I went from 1.9 2wd to my now 2.1 4wd and have to say I'm sure the 1.9 went better ... If that's down to the drive train drag I don't know ???

dumbo wrote:hi chris would like a bit more power for hills and over taking so my carb on on the engine and thats it ?? dont need petrol tank cause its getting to be lots more money?? cheer mate

I can't see how a different fuel tank would be needed - it's such a long way from the engine. And I don't believe there are any variations on the standard fuel tank anyway, other than a change to the diameter of the filler pipe. I'm no expert - still feeling my way along as you can tell from my other thread - but having looked at the two engines, and having heard other people's experiences, it seems like a simple swap. What year is your van - do you know if you have the early or late cooling system (early = thermostat under the water pump, late = thermostat on the left-hand head, bulkhead end)? Mine has the early setup, but even this should just bolt on as far as I can tell.

KINGPRAWN wrote:I went from 1.9 2wd to my now 2.1 4wd and have to say I'm sure the 1.9 went better ... If that's down to the drive train drag I don't know ???

That's got be either the extra drive train or poor tuning hasn't it? My own 1.9 runs very nicely too, but a properly set up 2.1 should have more power and more torque, so shouldn't it run even better?

Well it is only 50cc per cylinder ... My 2.1 went well I just remember being a bit underwhelming .. But having just gone to 1.9 TDI ... Now that's a difference:)

The 2.1 running on injection would need a different tank. But if you decide to stick with your carb and other gear, then your tank will be fine..

slowcoach wrote:The 2.1 running on injection would need a different tank.

You're right - I see Brickwerks do a tank for an injection setup that has a bigger outlet and swirl pot. What's the reason for that? What does the swirl pot do? Bigger outlet? - ok maybe I can see why that's needed to get higher fuel pressure, but does that mean there's a greater volume of fuel circulating all the time in an injection system?

thanks you all thats why i like the forum all this help swirl pot is for more pressure. van a 1986 so is a late one left side so should be easy?? so what about the carb jets setting up for running/tuning

CJH wrote:

slowcoach wrote:The 2.1 running on injection would need a different tank.

You're right - I see Brickwerks do a tank for an injection setup that has a bigger outlet and swirl pot. What's the reason for that? What does the swirl pot do? Bigger outlet? - ok maybe I can see why that's needed to get higher fuel pressure, but does that mean there's a greater volume of fuel circulating all the time in an injection system?

In injection tank also has a return line on the other side, feeding unused fuel back into the tank. (i dont think tha carb'd ones do, but i could be wrong there). There is a 'loop' of pressurised fuel flowing to, and through, and back from, the engine bay. I've not got a carburettor'd van, so am not familiar with them. But I do have an injected 1.9 with digijet. Youll lose some HP sticking with carbs (i gather), but you can offset that probably by setting things up 'just right'

dumbo wrote:thanks you all thats why i like the forum all this help swirl pot is for more pressure. van a 1986 so is a late one left side so should be easy?? so what about the carb jets setting up for running/tuning

It's all the same, the DJ is just a longstroke DG
just put the DG inlet manifold on the DJ plonk the carb on top, and there you go.
everything else is bolted to it...exhaust, cooling system etc
Use the DJ distributor

The only thing you have to do is change the water pump and thermostat housing to fit the oil cooler hose.

hi kev so you mean fit my dg water pump to the dj engine is that right and will the carb settings be ok?

if its a complete engine it should come all ready with water pump and stat housing all ready on it so just change the carb and manifold
i hope

If it's a complete engine, with the oil cooler, thermostat housing and water pump all attached, then they'll all be compatible. But if it's just a bare engine I think this means you won't be able to transfer your thermostat housing and water pump over from your DG because, although they'll fit, they won't have the extra spigots necessary to plumb in the oil cooler.

yes just look at some images of engines and parts the extra pipe from and pump to stat its a big learning curve so just checking