Club 80-90 Forums

Alright. going to swap my 1.9dg for a 2.1 dj. the 2.1 came from an automatic bus. can i use the clutch from the dg on the dj? kev

you need to check if the fly wheel on the 1.9 and 2.1 is the same as autos dont have flywheels

This has been covered quite a few times...

Use DG flywheel, but you must set the "endfloat" correctly, there is an actual measurement, but I cant remember what it is at the mo and no info to hand... but as a guide, flywheel installed and you should be able to pull the flywheel back (gearbox direction) and then push forwards and feel a "click".... feel nothing and its too tight so use thinner shims (always a combination of 3, never use 2..) if to much then you need thicker...

You can use all the DG cooling system (and fit the 2.1 pump with oil warmer/cooler) and the DG manifold and carb... this saves a bit of wiring and fuel pipe sorting..

If you are running LPG you can get away with 10 deg BTDC and superplus UL.. if not... you might want to consider 7.5 as a max on super+ and 5 on 95...

Worth rebiulding the carb at the same time too...

Let's start at the beginning how do i go about removing the flywheel

!!!!!!!!!!! er... maybe you should let someone else do it!!!!!!

Use a drilled steel bar to lock the auto drive plate in place so that they can undo the 5 socket head capscrews (10mm Allen Key) that hold it on ... there's a special bolt M18 x 1.5 x 50mm long with which to pull the plate off if it's still stuck.

Then you go down the road of fitting a spigot bearing in the end of the crankshaft VW 056 105 313 C fitted with the writing to the outside.

A late 2WD DG (1.9) flywheel and clutch are the same as a 2WD DJ (2.1)

As Si says ... if you don't know what you're doing get it done by a professional.

Ian.

I'm about to go down this route, i have an early 1.9dg and am going to fit a late 2.1 (both manual) retaining my carb/lpg.

Will the flywheel issue apply to me too or is this only an issue when changing between auto and manual?

Any other pointers will be helpfull.

Cheers.

Shep.

shepster wrote:I'm about to go down this route, i have an early 1.9dg and am going to fit a late 2.1 (both manual) retaining my carb/lpg.

Will the flywheel issue apply to me too or is this only an issue when changing between auto and manual?

Any other pointers will be helpfull.

Cheers.

Shep.

About to do a blow by blow of our swap ... owt I miss please ask.

Ian.

Double post .... sorry.

Ian

shepster wrote:I'm about to go down this route, i have an early 1.9dg and am going to fit a late 2.1 (both manual) retaining my carb/lpg.

Will the flywheel issue apply to me too or is this only an issue when changing between auto and manual?

Any other pointers will be helpfull.

Cheers.

Shep.

as long as you are replacing the clutch at the time of the swap, leave the flywheel on the 2.1 and get the right clutch for a 2.1 ,( thats what i did) no point in going backwards when your going forwards with the engine.....

and i would keep the early water sys on the van and swap the 2.1 to early water sys ( much better, less plastic bits ), but keep the late zorst sys.....

Cheers for the replies,

Mocki.....i was going to get a new clutch as amatter of course, so i should buy a new 2.1 then?

I was planning on keeping the 1.9 water system too but why the exhaust?
my 1.9 is quite new with a stainless silencer whereas the one thats with it is about knackered.

Is there that much difference in performance between the two?