Re-Titled - Fitting a DJ in place of a DF

[ajsimmo]

Early injection models such as the DH (1.9 digijet) had the temp 2 sender in the thermostat housing next to the gauge sender. Perhaps you could find an injection version of that part with the sender fitted.

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[Robsey]

Thanks chaps.
Your superior knowledge and input is greatly appreciated.

I suspect that finding a DH thermostat body will be quite tricky.
Google, ebay and catcar at the ready...

I will have a root around the van in the next day or two to see what is still piled up in the back, and what has been thrown out.

I have spent the past two weeks digging through my shed at home looking for parts that I have acquired along the way - still a lot more digging to do and hopefully a lot more elusive parts to find.

[Robsey]

Yikes!!
$225 plus tax and post from the USA,
or
£149-ish in the UK / EU.



It may be easier / cheaper to get creative with a hybrid set-up.

[Smiffo]

I think I mis-understood. I thought the original intent was to use the DF set up, but bolt the DJ in underneath?
i.e. Inlet, intake, Solex Carb, existing cooling setup stays the same.

Then, bolt on the bottom half ( block with DJ heads ) onto the existing?

Am I losing the plot? 
Tell me to shut up if I am lost lol.

[ajsimmo]

I think I mis-understood. I thought the original intent was to use the DF set up, but bolt the DJ in underneath?
i.e. Inlet, intake, Solex Carb, existing cooling setup stays the same.

Then, bolt on the bottom half ( block with DJ heads ) onto the existing?

Am I losing the plot? 
Tell me to shut up if I am lost lol.

So a DJ and Digijet it is...
And all my DF stuff to go on sale.

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[Robsey]

I am sure you are not losing the plot -
Sometimes I ramble so much that it gets confusing.

Anyway - I had an idea -
It is possible to drill and tap the existing casting to take the second sensor.
M12 x 1.5 should do it.





I presume that is all VW did.

The sensors are readily available from multiple brands including Bosch and Febi.
VW part number is 025906041.
(Not with A suffix as that is the standard clipped-in later style sensor).

And the bonus is, the sensor is less than £15 even from the more expensive suppliers.

I am sure that I could do it that way.

The sensor in the picture is one used for the Bosch Motronic 1.5 on my 1994 Cavalier C20NE.
It looks like the correct thread, however Febi do not show the same part number (or any number) for a DH set-up.

[Smiffo]

I think I mis-understood. I thought the original intent was to use the DF set up, but bolt the DJ in underneath?
i.e. Inlet, intake, Solex Carb, existing cooling setup stays the same.

Then, bolt on the bottom half ( block with DJ heads ) onto the existing?

Am I losing the plot? 
Tell me to shut up if I am lost lol.

So a DJ and Digijet it is...
And all my DF stuff to go on sale.

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Ahhhh.


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[ajsimmo]

I presume that is all VW did.

Yep, that looks about the right place.

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[Robsey]

Cheers me dears.

After a long absense from the van ( the unit owner has been ill),
I was able to dig through the back of the van to source all the removed parts.

The bonus was a very nice well-preserved water pump.



All the hoses "appeared" to be still there
The only item missing being the cap off the coolant tank (with level switch).
Looks like a metal bayonet style cap. Not a darlek.

The tanks were absolutely minging.
Full of 30 year old semi-dried sludge.



Whilst I was at it, I also grabbed the oil filler pipe and dipstick assemblies. They were in better condition than the DJ parts. Probably due to being inside the van since 1991.

[Robsey]

Okay - next daft question...

Which engine carrier and bearer bar should I use?
Early or late.?
Or does that depend on the exhaust.?

With respect to the exhaust, I only have the silencer and two support struts from the DF.
No idea where all the rest of the pipes went.

On the DJ, the silencer and the J shaped bar between it and the left knuckle would need replacing.

Many apologies for on going questions, but I think they are worth asking now

[Robsey]

Okay - dilemma time -
It appears that I am missing two main pipes from the old DF set-up.

One is still available from JK, but sold out everywhere else - The thermostat to rear of right cylinder head.

The other is the central metal pipe that virtually links all the outlets at the front of the engine.
Part number - 025121081C.
This is not showing as available anywhere.

The tube in question provides a mount for the carb heater switch sensor thingy as well as linking the front right cylinder head, DG, DF manifold / carb coolant supply, header tank main rubber hose, and the small bleader pipe on the main radiator circuit hoses.

One choice is to add in the later DJ thermostat to link all the pipework, the other is to get a metal pipe made up.

As you can see - ours was very manky ten years ago, and so was probably binned.





Any thoughts?

[Robsey]

Okey dokey -
I have looked at the USA DH set-up, and it looks very simple to reproduce.

So the main cross-engine tube needs only three stubs (ends).
One medium dia stub on the right-hand side from the heater matrix hose.
One small dia stub for the bleeder valve connection.
And a medium dia stub for the header tank hose.



Another question - the front left cylinder head junction where the later thermostat would go.
On early engines, this is used to heat the carb manifold. On injections the manifold is not heated.

I presume I can just blank off the front left port?

Or should I vent it into my cross-engine tube in a similar way to how the right manifold coolant pipe does on the carb set-up?

All the pictures that I can find hint at the port being blocked off.

From a Samba thread.



From Bentley's



My worry / concern is that I am already removing the oil cooler, and now blanking a coolant port.
Therefore - would this risk over-heating.?
I live in the north west of England, so not exactly tropical, but I want to be sure that I am not "excessively" compramising the cooling system.
VW updated everything after 1985 for a reason.

[Robsey]

Okay - next daft question...

Which engine carrier and bearer bar should I use?
Early or late.?
Or does that depend on the exhaust.?

With respect to the exhaust, I only have the silencer and two support struts from the DF.
No idea where all the rest of the pipes went.

On the DJ, the silencer and the J shaped bar between it and the left knuckle would need replacing.

Many apologies for on going questions, but I think they are worth asking now

After pulling the remnants of the DF out of the van, I can see that I more or less answered my own question.

Early exhaust requires the early engine mount and moustache bar.

Later exhaust... later mount and bar, because of the big mounting hooks used on the later exhaust.

I am getting about 85% there now, but I will need to fabricate my own DH style cross-engine coolant pipe.

[slowcoach]

Hi robsey-
I used to have a DH engined van, originally from Australia. I've now gone Subaru, but I may well have photos if you need. My memory may be a bit foggy, been a few years, but do ask if you need any help, may be able to help!

[slowcoach]

PS it was early cooling setup too. I've a couple of videos of the engine bay running which might show some light on the setup, just before it was removed. Let me know and I can get them to you, via pm