DG Swap

[sump]

Hello Chaps

Putting another 1.9 DG into my 88 E reg van and I've encountered a slight problem.
My van has the earlier I believe pre 85 set up for the cooling system and exhaust. The exhaust isn't a problem but the water side is causing some brain scratching as the newer engine that came out of an 87 D reg bus has the later water pump and pipework.

What would those of you with far more experience than me do? Fit the earlier pump or what?

Thanks in advance!!

[Mocki]

You have two options , either make the later engine fit the early van ( water pump and earlier pipes )
Or make the early van fit the late engine . A much bigger job, entailing quite a lot of work , but bringing benefits for the future
You will basically need everything from the front to back rad pies back , including the coolant distribution tower from behind the baulkhead , the bleeding ring from around the inside of the engine lid , the header tank , and carb pipes , thermostat housing ect ect

Everything is inter changeable from any DG , early or late , all the bolt on bits will fit , but do not mix and match !!

[sump]

Hi Steve

Sounds like I need to adopt your 1st proposal! Make the engine fit the van.

What do I need to do?


 

[Mocki]

Take the old water pump and thermostat housing off the old engine and all the associated pipes and swap them onto the newer engine , the newer exhaust will fit with the older cooling system , it will be close tho
Early water pumps were available from brickwerks two weeks ago …. Check now, you would be as well to fit a new one if you can get one

[ajsimmo]

Take the old water pump and thermostat housing off the old engine and all the associated pipes and swap them onto the newer engine , the newer exhaust will fit with the older cooling system , it will be close tho
Early water pumps were available from brickwerks two weeks ago …. Check now, you would be as well to fit a new one if you can get one

That's if you can get the water pump and thermostat housing apart. If it was all good on the old engine, maybe just swap it as a complete assembly to potentially save yourself a world of pain.

Sent from my moto g(30) using Tapatalk

[sump]

Thanks for all of the advice much appreciated 

Fingers crossed then!

[Robsey]

, the newer exhaust will fit with the older cooling system , it will be close tho

I fitted the old cooling parts to my 2.1 engine.
My casting was touching the exhaust pipework.



I dressed a little bit off the thermostat casting.
It is a nice fit now, without weakening the thermostat.

[maxstu]

, the newer exhaust will fit with the older cooling system , it will be close tho

I fitted the old cooling parts to my 2.1 engine.
My casting was touching the exhaust pipework.



I dressed a little bit off the thermostat casting.
It is a nice fit now, without weakening the thermostat.

There's a heat shield that wraps around the finned outlet/inlet. Did you manage to fit it , too?

[Robsey]

Yes I did...
It was the projection on the thermostat housing - the fathest left part in the photo that was touching the exhaust pipe.
The heat shield was okay.

Not sure if you can see the area with orange marker pen on.
I just rounded the edge to clear the pipe.