Club 80-90 Forums

So much for the 50p clip I thought was the culprit.....(see yesterdays thread).

Went to fill up coolant today after replacing thermostat sensor clips with new plastic ones - and coolant continued to pish out all over the floor. Traced it back to running round the rubber gasket on the LH head - by pushing on the gasket I could slow the flow - I reckon about a third of the way back on the top side was where the leak is coming from.

So - my inital thoughts - after doom and gloom over all the implications are:

Tis a 1991 model - 1.9DG 86k miles- so is there any chance getting the engine dropped - and head off - could actually be reasonably straightforward (had VW fixed the rotting head stud problem by then) - or am I likely to be better off looking at recond engine replacement......

The LPG conversion just paid for itself over the last year - I hope I can transfer this over relatively easily to a recon - if I go down that route.

I would love to go down the 2.1 route to replace the 1.9 - for that bit of extra - is this straightforward?

many more questions to come....!

With just 86K I think I would check the possibility of replacing the gaskets first. The engines are supposed to be straightforward to remove but finding a garage to do it isn't. I'm not sure and, like you, would be tempted to bite the bullet and get a recon, new exhaust, clutch all at the same time and hope that it lasts another 15 - 20 years. Gasure do engine replacements, but you have to run the new engine in using petrol only.

Very sorry to hear your news, especially with all the bodywork that you've been doing recently. Hope it doesn't take long to get your engine sorted.

Tony

mikey9 wrote:I would love to go down the 2.1 route to replace the 1.9 - for that bit of extra - is this straightforward?

I don't think it's straight forward . . . not judging by some of the posts I've read on here anyway, but I've got no first hand experience of it myself so could be wrong with my conclusion!

Tony

Having read posts on here about gasket renewal and read the Haynes/Bentley manuals I would probably hire a hoist and have a go and post questions as I went along if there were aspects I wasn't sure of! A lot of people do their own head/gasket repairs and, with just 86K, would imagine your engine still has a lot of mileage left in it. How was it performing before disaster struck? My local garage mechanic said he would be happy to do an engine replacement but not keen on renewing the gaskets. I would stay with the 1.9 and avoid any additional complications/costs.

Hi Mikey
replace the gasket on problems with studs on your engine just be careful with the exhaust studs
give them a good soak with Wurths rost off ice
I've not been in Nuir of ord for years must visit up that way soon

cheers George

Having a good search this morning and various previous views suggest getting the water jacket seal replaced - or going don the recon route..

Concerns with the former are:
1. - If I have the LH one done - prob should have the RH one too
(also a very small weep (1 drip per hour?).
2. - If I go with the above - I will replace the exhaust and whilst engine is out it seems sensible to have clutch done.....
3. - Finding someone around Inverness who is capable - willing to do the above - and well....
4. Cost?

Concerns with the latter are:
1. - Which reconner - Elite, Remtec, Vege - anyone else? - I will replace the exhaust and whilst engine is out it seems sensible to have clutch done.....
1a. - Am I throwing away an otherwise perfectly good engine (with "only" 86k miles) just cos the rubber seal(s) have perished in 18 years.....now that is totally against what I do - reduce/reuse and recycle!
2. - Finding someone around Inverness who is capable - willing to do the swap.
3. Cost ???(900 Elite, £1900 remtec - both plus surcharge, shipping and fitting...?500??) plus exhaust, plus fittings, plus any tired ancillaries....please suggest alternative numbers as appropriate.....!

aaaaaarghhhhhhh............dispair........

Mikey,

firstly, 1.9 to 2.1 easy swap, especially if you keep the carb and run the 2.1 on lpg through the carb. Many members with this set-up. With the help of one chap we did a 1.9 to 2.1 transfer in the carpark (8 hours)at the back of the house, and did another 1.9 to 1.9 (another van) with a friendly mechanic who helped us and let us use his workshop on a saturday - so we learnt a bit about engine removal and refit too. That took just over 8 hours, but I did drive it home on the replacement engine!

secondly, transferring LPG system to new engine....also easy as you don't touch any of the fixed pipes or the vapouriser. Just the ring on top of the carb to remove, then tuck away all pipes to one side to remove engine.

Engine hoist makes life really easy. Only hassle is early water system....but you have the late system, so that's a bonus! Also need a good trolley jack and some decent axle stands! A couple of sets of hands to guide the lot out of the way is useful too!!

Your engine hasn't many miles on it.....whether you "have a bash" is up to you. I know there are many on here that will help with advice, and if you take it slowly and post pictures, you will get plenty of advice.


Good luck, hope the earlier points add a little brightness to your dark place (been there...know what its like...)

oh - replacing clutch isn't too difficult either. Again, assistance on here - we managed it with the clutch aligning tool. About £80 for a kit and self-fit.
Em
x

Hi Mikey, not sure how bad the leak is but before spending loads of well earned money have you considered a product called "K Seal" its a coolant leak repair. Its a fluid you add to the coolant. It mixes with all antifreeze and "permantly" seals most leaks in engine blocks,cylinder heads, head gaskets, radiators etc. It costs around £10. but may be well worth it. Don't forget there's an "O" ring required as well as the plastic clip to hold the sensor in place. Good luck Stewart

Stew - thanks for the tip however the leak is .....a proper LEAK - as in it was running out rather than dripping.

I have some Wynns Radiator Stop Leak sealant (recommended on the wiki) - but I think we have gone beyond this kind of remedy....

It won't cost you anything to take the head off and have a look. if the studs break, they were going to anyway.
An elring head set from GSF should be around £50.
Elite or Remtec? Elite. Ask them to fit solid lifters and a type 1 cam.
2.1? twin carbs on the combination above will make it feel like a 2.1!

Laurie (and others) thanks for the replies....

Good to hear a recommendation for Elite from someone who knows a lot!

Am getting at the stretch of my comfort zone a bit but learning fast.
An "elring" headset - what does this mean please?

Are you suggesting if I went with Elite I could request a Type 1 (?) cam and Solid Lifters (I am pretending to understand this bit - will do a bit of googling/reading later).

I have seen your posts on twin carb setup on 1.9 - as i have one of Steves LPG conversions - I want to retain this - do you have any experience of such a combo - with a gas setup - or if Steve is reading.....?

Please keep it coming - it is all very useful.

Ok, the leaking head is off - the rubbers seals are perished from the inside out - don't know if the head surfaces would clean up.

(Here I am quoting what I have been told)
The cylinder liners are loose, so i am told the gaskets they bed onto need replacing - which is split the crankcase job etc.

My garage is not keen to go down this route (not a W/C VW specialist - b ut I guess our nearest is 3.5 hours away in Glasgow!) due to the significant amount of work (and prob the fact they haven't done one for years!)

So - my course of action

A Wanted Post for DG Engine (see Wanted)
Quote from Elite of £760 plus £65 delivery plus £150 surcharge

Any other suggestions?

I would be tempted to go for the exchange unit and be done with it unless a very good used engine was available from a trusted source. You have a guarantee, consumer protection and the price seems very reasonable.

E D I T Theres two for sale (just in case you missed them), Syncro spares looks a good un!

mikey9 wrote:
I have some Wynns Radiator Stop Leak sealant (recommended on the wiki).

I've just read that article on the Wiki where they recommend Wynns. Is it the cooling system stop leak in the round metal tin or the blue plastic rad and cooling system stop leak? both products are by Wynns or are they both the same!