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Sun Mar 25, 2012 11:20 am

I recently purchased a 1984 Vanagon. The motor needs work and I've been looking at all of my options. It has the 1.9l gas motor right now. I'm really interested in the TDI motor swap. I know that there is probably a post that has the "average cost" to do this but I can't seem to find it anywhere. I've looked into the bostig ford focus swap and wanted to compare to a diesel swap. I've search a good bit and can't seem to find the cost of the diesel swap. If anyone could point me in the right direction of a previous post on the pricing I would greatly appreciate it.

This is my first VW, I've always wanted a westy now I have it and it's time to get my hands dirty and get this thing running. I'm not completely against fixing the 1.9l gas engine I was just looking for something a little better on fuel.

Thanks,
CJ

Sun Mar 25, 2012 11:29 am

The Diesel AAZ tdi engine swap is the easiest and most stress free.
All the fittings are there and the engine is readily available in a lot of cars.

Petrol to Diesel conversion parts
Parts needed
T3/T3 Diesel parts
Engine support bars (late type)
Alloy engine mounts
Diesel bell housing
Diesel starter motor
Flywheel (1Z for tdi conversion)
Clutch (1Z for tdi conversion)
Sump (with turbo oil return)
Oil pump
Oil filler tube
Dip stick and tube
Inlet manifold Turbo
Exhaust manifold Turbo
Turbo charger
Turbo oil return pipe
Exhaust middle pipe
Exhaust silencer
Exhaust support brackets
Battery tray/header tank support
Header tank
Water hoses for engine
Thermostat housing
Electric water pump
Alternator and bracket
Air filter box and brackets
Induction pipes
Engine fuel pipes (no cracks)
Fuel filter
Diesel fuel pump
Diesel wiring loom for engine
Vacuum pump
Extensions for water pipe/hoses

Sun Mar 25, 2012 3:12 pm

This chart appeared some time back:

http://www.thesamba.com/vw/forum/viewtopic.php?t=4...p;start=20

But the topic is rife with opinions and subjective assessments so no single chart can tell the whole story and certainly no consensus exists.

Sun Mar 25, 2012 3:41 pm

Wow, That chart is awesome! I know that the prices will vary but it gives me something to go by, I still may try to get the engine fixed that is in it I just wanted to get an idea of all the options out there. Thanks for the quick replies!! My eyes were going double reading all the post haha!!

Sun Mar 25, 2012 4:17 pm

Ahwahnee wrote: This chart appeared some time back:

http://www.thesamba.com/vw/forum/viewtopic.php?t=4...p;start=20

But the topic is rife with opinions and subjective assessments so no single chart can tell the whole story and certainly no consensus exists.

Boy, many of those numbers are way off - who made up those figures? :(

Sun Mar 25, 2012 7:57 pm

Hello CJ,

Welcome to the Samba. ’84 Westys are a popular year for sure. What is the status with the engine as it sits?
I find the 1.9 a very simple and easy engine to work on with abundant parts for reasonable money. Doing the work yourself is even better for saving coin. Do you have wrenching skills?

In the meantime be sure to post some pics of the new-to-you camper so we can see the goodness. Many of us have been down this road and are pleased to share any/all shortcuts with you.

In regards to fuel economy; it is all in how well the engine is tuned. My rig gets constant 20-21 MPG in part because the driver is the mechanic (me) and treats it with due respect for the old-bird it is.

Cheers,
Jeffery

(Westfalia travel/camping videos at YouTube link below)

Mon Mar 26, 2012 3:48 pm

Hey Jeffery,

The status of the engine is well running rough, I think I could possibly get lucky and change the distributor cap, rotor button, plug wires, and plugs. I bought these today and the guy gave me the wrong stuff, :cry: , This was even after i offered my vin number multiple times. I still don't quite understand the chassis number, I think I have it figured out. Apparently the guy behind the counter doesn't understand either I guess he was just going to guess haha.... Enough of me venting. haha... I also think I will have to replace the radiator I haven't dropped the spare tire but I am thinking that it is leaking a little when it runs.

I work in a machine shop so I think I can manage working on the van. In depth motor work I may shy away from just so I don't end up causing more problems.

Where is the best place to get a new canvas for the pop top? I have found a few online but I may not have found the cheapest/best deal.

CJ

Mon Mar 26, 2012 7:55 pm

Hey CJ

Rough running could be almost anything; but the basics of fuel and spark are key ingredients. Cap, rotor, plugs and wires are a great start. Look for worn or rotten vacuum lines too. Make certain the grounds are clean (on yours they are on the left side of the engine bay) and fuel filter is not plugged.
.
Sorry the dude gave you the wrong goods.
If you can plan the purchases use handy vendors such as Van-Café.com, cip1.com, autozone.com or GoWesty.com to get the best parts match for your vehicle. As for the pop-top tent…check out the Samba forum for reviews of the various vendors and materials available. Cheapest may not always be the best option. Your original top is canvas, so consider how close to OEM you wish to keep. Either way the project is a day-eater.
.
Remember the wealth of information here on the Samba and the links therein. So how about some pics of the rig?

Cheers,
Jeffery

(Westfalia travel/camping videos at YouTube link below)

Tue Apr 03, 2012 5:14 pm

Hey sorry I haven't replied back yet, I've been really busy. I am in the process of making room in the garage to pull the motor out of the Westy. I think I may have a blown head gasket or cracked head. Here are some pics they are rough just cell phone pics.

Excuse the mess I was cleaning it out when i took the pics.

Sat Apr 21, 2012 6:45 pm

Removed the camper top today. Bleached the top to kill/remove the mold that had formed on the top. I left the top off to give me more clearance to jack it up in the garage.

I've been researching the aba 2.0 with 1.8 head, but I've yet to figure out for sure if you can do this under the deck lid. I've seen conflicting info. I really don't want to alter the deck lid if i can help it.

Thanks,
CJ

Sat Apr 21, 2012 6:57 pm

with the 2.0 with 1.8 (counter flow) head you should fit under the decklid, but you WILL have to notch/modify the DS rear frame rail where it impacts the intake manifold.
not really a big deal since thats what any of us with non-Tiico inline 4s had todo to fit

so just to prepared for minor compromises either way you go..

Sat Apr 21, 2012 7:34 pm

Is this accomplished at 50° or 15° ? I believe I've read where you have said it is the 50 ° and use some diesel components (oil pan, oil pump & pickup, engine mouting bars & mounts). I found the fastfoward system for engine mounting or are the diesel mounts easy enough to find and use?

Also as far as the electrical/wiring harness issues. I remember reading you saying something about digifant being easier to go with (which is 87-92), how much more efficient is the newer models? How much more difficult are they to deal with? Just asking incase i found a killer deal on something newer. . .

Dan I honestly was hoping you would respond to my questions due to the fact you seem to very knowledgeable on the ABA swap.

Thanks,
CJ

Sat Apr 21, 2012 7:37 pm

I'm trying to remember who sent me a tutorial on converting to an AAZ TD. Think it was an American from Limbobus > John. I'll look my copy up.

Did anyone suggest that you change your fuel lines if you are gas, get a Bentley, hear there is a new hard cover one which is superior to what most of us have. Lots of great vw vendors for us and look for this in Samba Classifieds. You can even put a WTB (wanted to buy ad in) and keep an eye on the sticky "Karma part it forward:.

Enjoyed the work and enjoy the highs you'll feel. Welcom

Sat Apr 21, 2012 7:59 pm

Already have the bentley purchased from thesamba.com. I haven't messed with the fuel lines as of yet. I plan that in the future I have a bigger issue than that at the moment hope to drop the engine this week or at least by next weekend if my week allows haha...

Sat Apr 21, 2012 8:25 pm

If it's gas and you are going to be doing any driving, change the fuel lines. Don't put it off once you start driving and carry 2 fire extinquishers.

Sat Apr 21, 2012 8:51 pm

yes it is gas, its the 1.9l waterboxer motor. I'm considering doing a swap unless what i find is a cheap cheap fix... Considering the 2.0 aba swap..

Sat Apr 21, 2012 9:12 pm

AHA, I was towed in Chattanooga in Dec2010 in my Westy. Really nice people owned the tow truck and a beaut of a shop. They fed me and took very good care of me. Must dig up their business card.

Sun Apr 22, 2012 5:01 am

Being a 'noobie' it seems u have a lot of 'ithink i have this problem' s. What makes u think the engine needs to come out???GET another opinion from an experienced wbx owner instead of jumping off in eager haste when not necessary. If u can't conquer these problems with the bently and advice here , u r in for a real can of worms jumping into a diesel swap. Back off a bit. my new ,1st one bit me a few times the hard way as i was ina hurry, my 2-cts, enjoy the journey.

Sun Apr 22, 2012 7:38 am

Noobie or not the motor needs to come out, I'm not a complete moron. I know the left head has to come off and I would prefer not to work on the motor in the van. I have a very bad feeling that the head is cracked. The amount of water leaking out of it makes me believe that, it could be a gasket but if so the thing is completely destroyed. Also everybody has to start somewhere when learning. . . If the motor is fixable within reason yes I will put it back in... I am more leaning towards the 2.0 aba motor now not the TDI.... Which is a gasoline motor :)

Sun Apr 22, 2012 6:24 pm

It was cool and windy today I didn't get anything new accomplished. I did how ever catch the tail end of bugapaluza in Chattanooga.. Wish I had made it out on Sat to see more of the vehicles. I will try to post pics of the westy topless tomorrow. Good Evening!!!!