Club 80-90 Forums

As some of you may know I recently, well last summer replaced my 1.9 DG with a 2.1 DJ crank and pistons as well as cam shaft after which I had no end of tappet problems and breaking valve spring problems. After a full set of new valve springs and about 2500 miles under it's belt all done locally I finally risked a journey in it To Aberystwyth and back to Bromsgrove using the A44. This journey I had done many times with the old DG engine in, as my Kids were at Uni there. So here are a few differences I have noted,
1. I can now overtake faster moving vehicles than tractors (even they were a problem before with the DG) Today a large Crane, a horse box behind a disco and a corsa were all dispatched behind me.
2. Increased velocity up Bromyard heath I used to manage 28mph but today 35mph.
3. Increased driveability in the mountains now I just can't get round the corners fast enough or brake well enough!!!
4. Increased velocity up the hill in Aber by the Uni. Used to crawl up at about 25mph, today 35mph.
And the best thing so far!!!!

I managed over 200 miles from a tank of LPG. My tank takes 48 litres. With the DG we managed a maximum of 17.5mpg on this journey. Today with still quite a stiff engine 19.5mpg with the DJ. I'm pleased with that.
(Still running the pierburg with mixer ring, the Blos is still giving me trouble so I'll try to get that back on in the spring)

Next project corsa c power steeing and a BMW brake servo.

Thanks for the update.

previous theads below for those that are interested...

I decided to reuse old tappets in my DJ build because of your problems, fingers crossed.

I have one lazy tappet in the DG and I'm wondering how to find which one.

https://club8090.co.uk/forum/viewtopic.php?f=37&t=148330" onclick="window.open(this.href);return false;
https://club8090.co.uk/forum/viewtopic.php?f=37&t=153699" onclick="window.open(this.href);return false;

not sure we ever got a pic fitted?

E D I T here it is...

Thanks Itchy I had forgotten how nice it looked in it's new home!!!

That's one nice looking engine

Ant-t wrote:That's one nice looking engine

That it is, you could eat your dinner off that. Good Job.


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123-jn, can I ask please did you use the early 1.9 con rods with standard bolts in your build?
2.1 and later had stretch bolts that shouldn't be reused and are NLA ( other than buying with NOS con rods)
I'm interested to know that it's possible to use early bolts.

HI , I used the rods from the 2.1 DJ donor and removed the stretch bolts. Instead I used normal bolts non stretch from VW heritage. The rods from the 2.1 donor were identical to those from the original 1.9 case but were less worn at the small end so Rather than replace the small ends in the 1.9 rods I used the 2.1 rods reusing the small end bearings and pins which were basically unworn. The bolts from heritage don't have the odd shaped heads that lock in the cap casting recess instead they are just dome heads but due to the splines on the bolts they don't move once pressed in anyway. Strangely enough neither of the rod sets had any ovality to measure at all. I have another set from an MV which are also nice and round.

I forgot to say that in my DG I reused the stretch bolts after careful measurement somewhere online I found a guide that told you how to check them for length. It managed 30000 miles without any problems and was nice and tight when I stripped it again to rectify an oilway blockage problem. Maybe a 2.1 DJ would put more stress on used bolts? One day I will find another crank and pistons for a DJ and rebuild my spare 1.9 as another 2.1!!