Metal water pipe 1.9df or dg? 025121081d

[Boneyt25]

My 1983 1.9 think df with some dg parts. Has developed a porous metal waterpipe across the top of the engine.

Last post I can find was 2011.

Any solutions to replace this part are welcome. Tried the usual websites to no avail.
Partno.
025121081d

[maxstu]

Three options open to you...

Try Mick Crowe for a secondhand part.
Tel. 07968367046

Convert to later style cooling system. About £200. But all parts readily available for many years to come.

Test your plumbing skills and replicate the pipe in copper tubing. Have seen it done many years ago. Even down to the coolant sensor outlet by braising a fitting nut on the side of the main copper pipe.

[Smiffo]

I know @Robsey was looking for one a few months ago, and was struggling ( I think. )

There is this chap selling parts for what looks like an old coolant system: 

https://www.facebook.com/marketplace/it ... d5ad1f755e



 

[Boneyt25]

Cheers both,

Good news on another front...
So have established that the engine code is dg not df as first thought.
Not that this makes too much difference to the problem in hand as far as I'm aware. But is the silver lining of the day!

Not favouring second hand as it'll probably not be much better than what I've got.

So that leaves 2 options.
I was thinking the same about fabricating out of stainless bits and silicone, rather than copper. But as mentioned. There's a couple of obstacles. The temp sender, and the mounting brackets. Both could end up looking pants very easily with the tools available. Not sure if my stick welder will be friendly with stainless!

I will investigate the final option. For some reason I hadn't considered this. Just assumed they all had this pipe. To be fair most coolant parts are showing age so 200 doesn't sound too bad ....

[Boneyt25]

Do you know if its as easy as buying one of the full hose kits off heritage or jk and slapping it in.
Or is there any known obstacles, like plastic connectors etc. That they would assume are pre existing.

The diagrams I have found so far are a bit clumsy for trying to visualise.

I can feel a piece of rubber and jubilee clips getting slapped on there for a couple of weeks at this rate.!

[maxstu]

Add a few hood close up photos of your van's engine bay to show what is what.

If you move to a later style cooling system you can sell off the redundant parts on here.

Off the top of my head, you will need...

Expansion tank
Thermostat housing
Coolant distibutor
Metal water pipe
Waterpump
Both side heads' spigot pipes.
Thermostat to coolant distributor hose plus a few o rings here and there.

Not sure if your van is fitted with the coolant ring running around left side of engine bay?

[ajsimmo]

I'm not sure how an early cooling system can be converted to late for £200, especially given your aversion to using used parts. There are so many things to change, including the main F-R coolant pipes, and everything back from that. Distribution tower behind bulkhead, all hoses, thermostat housing setup, water pump, that big pipe between WP & TH (that's over £100 in stainless), bleed rail, pressure tank, and a lot of work. To do it in new parts, I think it's the best part of a grand.

Sent from my moto g(30) using Tapatalk

[ajsimmo]

Add a few hood close up photos of your van's engine bay to show what is what.

If you move to a later style cooling system you can sell off the redundant parts on here.

Off the top of my head, you will need...

Expansion tank
Thermostat housing
Coolant distibutor
Metal water pipe
Waterpump
Both side heads' spigot pipes.
Thermostat to coolant distributor hose plus a few o rings here and there.

Not sure if your van is fitted with the coolant ring running around left side of engine bay?

Ha, snap! You type faster than me

Sent from my moto g(30) using Tapatalk

[maxstu]

I don't think so! I started my reply just after BoneyT25 last post.

[maxstu]

I must be out of touch with today's prices.

I would imagine it's the coolant bleed rail that is the costliest part. And if it can be sourced, of course?

While stainless is best. An equivalent mild steel pipe instead of stainless costs about £40 from JK.

Otherwise Brickwerks for the rest. I did have a quick look and reckon (covering most parts) a layout of around another 200- 250 quid.

So my advice is to brush up on your copper soldering skills.

[Boneyt25]

Hahaha,

Yeah you're not kidding!

That's alot of wonga , I've also been looking and trying to work out what bits. Plus not wanting the van to be off the road for too long.

It seems these systems are quite different considering
Does this mean the early system is complete pants...in other words, is it really worth it.?
I'm surprised by the front to back pipes and water pump. And expansion tanks ...all being required. Not saying your wrong. Was just wishing it wasn't the case!

Since I'm not quite prepared to blast 600 plus notes at it over this one sodding pipe.! As there are other bits requiring both my attention and funds . I will proceed with a copper pipe super bodge as suggested...

I will post pics of the engine bay. Maybe tomorrow.

Once I have created a copper and solder abortion I will also post pics of that!

In the meantime, is it a quicker job to detail which parts are common to both systems. Especially those available in ss.? As if the repair works well then I will perhaps start purchasing these.

[Mocki]

The water pump, thermostat housing and header tanks will need to be swapped over , the above list from both above members is correct .changing from early to late is a major undertaking …. If it was me i would ringing one of the breakers and getting a good used crossover pipe , mick crow on the number above (if you can get him to answer the phone ) or maybe BIg Red or whatever they are called this week , on Facebook , or more reliably https://www.partsemporium.co.uk/. Julian is a long term member of this club and very knowledgeable.

I suggest you take a good clear picture of the part you want before contacting anyone over the internet so there is no confusion!
The DG crossover pipe is different to the DF one , so dont get the wrong one

[maxstu]

Not 100% certain any parts cross over, to be honest. The link pipes behind crank pulley are the only parts l can think off. Thermostat?

You could get away with using early an expansion tank and cobble together a coolant hose to fit.

If you go on Brickwerks website and search T3 coolant parts you can view what fits early and late vehicles. .....dismiss coolant pipes for 2.1 oil cooler.

My previous camper had the early cooling system. I actually preferred it for simplicity and ease of maintaining. Especially with the metal thermostat housing right under your nose, instead of a plastic box fitted a back-breaking distance away.

Just that pesky and rare cross-over pipe

[Boneyt25]

---

Well ive measured up with a view to a copper bodge up.

On closer inspection im surprised this pipe isnt leaking else where. I took some pics of the engine bay but cant see how to post without using the url function? 

I will have to see what the future holds. One thing for sure I cant face driving it more than 10 miles with the current pipe now I've seen it.  

The external of the bulk of the pipe is 25mm so im planning to go 22mm copper with yorkshire couplers as outlets(ends) so that existing hoses fit and the rib should decrease risk of pipes blowing off. 

Then ill also need a temp sender piece which i might try and solder a nut in. But will have to see if thats viable. Or put inline.. 

All good fun. 

Will work out alot cheaper for now. 

Only had the van a couple of months. So I'm sure there's some more skeletons in the engine bay alone! 

Ha

 

[Boneyt25]

Sorry missed your earlier post about parts and pics.

See if this works.

Before you mention how bad it looks in there, yes I plan to have a good tidy up.! But it didn't miss a beat when I bought it and drove it home 252miles ...... with national recovery cover in place naturally! Lovely old machine!

That being said, feel free to point anything out as this is first vw!

I'll email and call the parts people. Might save me alot of time and agro!

Cheers