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revolution337 Samba Member
Joined: May 23, 2009 Posts: 372 Location: Pennsylvania
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Posted: Sat Oct 13, 2018 1:58 pm Post subject: My air-cooled to 1.8t build |
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Hello all! I've been lurking for a long time on the Samba, and felt that I now actually have some decent material to contribute.
After much reading and debating, I've decided to pull the trigger on installing a AEB 1.8t into my '82 air-cooled westy. I've thought long about it, contemplating other engines, buying a water cooled van instead, etc etc. But I have become quite attached to my current van and want to keep it for years to come. Installing a more modern power plant will greatly help in achieving that! I understand that this is be quite an undertaking, what with having to installed and entire cooling system from scratch. I enjoy working/wrenching on cars, (VWs mostly) so I don't really mind the extra work.
I'm sure I will have questions/roadblocks along the way and I'm hoping that by having this build thread, it will be easy for the Samba community to help me out! My aim is to also have this thread serve as an informative data base for any future builds someone may have.
So it begins! Here is my starting point. 1982 Vanagon Westfalia, with a center mount progressive carb kit installed (runs great, when it runs great!)
So long my friend
In comes the donor vehicle. 1999 Passat 1.8t with 166k miles on the clock. Bought it locally as a "mechanics special". Pretty rough cosmetically, but mechanically it is in good shape. Was able to drive it home, and tested the entire power band. No issues or hick-ups. Gives me much more reassurance vs buying a used crate engine and taking someones word that it "runs great!" Only fault codes it had were P0420 (catalyst efficiency below threshold) and a large EVAP leak. I'm not going to be using either system so no big deal to me. Had the engine pulled out in a weekend with some help from a friend.
Pick up a few items necessary for the air cooled to water cooled aspect of the build. A complete heater box assembly with heater core, instrument cluster with tach, and lower radiator grill (in case I decide to cut up the front end for more air flow)
The heater box was an absolute mess, but cleaned up very well. Took the whole thing apart and cleaned/scrubbed the entire thing with soapy water. Wire brushed the flaps to remove all the rust that had accumulated over the years. Bead blasted the flaps and metal core insert as well to further help the cleaning. Hit it all with a fresh coat of rustoleum paint to combat future rust issues. Started installed fresh new foam on all the flaps. I currently have a new heater core and blower on order. Once those arrive, I will reassemble the box.
Door on the left before cleaning, door on the right after cleaning.
Ewwww rust!
What a mess
Cleaned and painted, starting re-foam process
Also started tearing apart the 1.8. Started by cleaning the valve cover and intake manifold, and prepping them for paint.
New timing belt kit.
What I've posted thus far has been about a month of work. Now that this thread it up, I will try to keep it updated with my progress more often. Cheers! |
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valvecovergasket Samba Member
Joined: October 10, 2018 Posts: 1491 Location: pnw
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Posted: Sat Oct 13, 2018 2:02 pm Post subject: Re: My air-cooled to 1.8t build |
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Awesome looking van!
Whats the plan for engine mounting and intake/intercooler/exhaust stuff?
Pretty new to vans so curious what's regularly done
Looking forward to seeing how the build goes! |
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Vanagon Nut Samba Member
Joined: February 08, 2008 Posts: 10361 Location: Sunshine Coast B.C.
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Posted: Sat Oct 13, 2018 2:19 pm Post subject: Re: My air-cooled to 1.8t build |
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Watching this thread!
Thanks for the pics and descriptions.
Random air to water cooled swap thought. Granted, I'm thinking in terms of converting USD to CND but for the cost of 1.9 stainless pipes, (they're more than the 2.1 pipes??), and I know this has been done, but I'm curious of feasibility & life span, possible savings of using marine bellows hose in lieu of coolant pipes. Or is that a "fools errand" over the long term?
I wish I'd installed the heater core perforated metal piece. Not that you weren't installing it but it seems its' purpose is to slow air passing over core fins. In colder ambient temps, that may really help increase heat.
Neil. _________________ 1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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revolution337 Samba Member
Joined: May 23, 2009 Posts: 372 Location: Pennsylvania
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Posted: Sat Oct 13, 2018 6:22 pm Post subject: Re: My air-cooled to 1.8t build |
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valvecovergasket wrote: |
Awesome looking van!
Whats the plan for engine mounting and intake/intercooler/exhaust stuff? |
Engine mounting will most likely be a modified OEM mustache bar, fabricated to accept the stock AEB motor mounts. Intake will be pretty simple, and intercooler will be an air/air unit in the passenger side D-pillar area. Exhaust will be catless with a muffler running along the rear bumper area, exiting the passenger side rear.
Vanagon Nut wrote: |
Watching this thread!
Thanks for the pics and descriptions.
Random air to water cooled swap thought. Granted, I'm thinking in terms of converting USD to CND but for the cost of 1.9 stainless pipes, (they're more than the 2.1 pipes??), and I know this has been done, but I'm curious of feasibility & life span, possible savings of using marine bellows hose in lieu of coolant pipes. Or is that a "fools errand" over the long term?
I wish I'd installed the heater core perforated metal piece. Not that you weren't installing it but it seems its' purpose is to slow air passing over core fins. In colder ambient temps, that may really help increase heat.
Neil. |
I've done a lot of reading about that heater core metal piece and decided that I will be reinstalling it, as it seems to benefit most.
In regards to the long coolant lines, I'm undecided at this point which route I will be taking. I've read about numerous people running the long lengths of marine grade rubber hose without any issue. Most of what I would consider to be "quality hose" is pretty pricey though. I did a rough calculation and it would cost about the same as purchasing the SS lines. I still have some time to figure out which option will work best for me. |
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MarkWard Samba Member
Joined: February 09, 2005 Posts: 17057 Location: Retired South Florida
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Posted: Sat Oct 13, 2018 6:25 pm Post subject: Re: My air-cooled to 1.8t build |
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Shameless plug, but I stripped the cooling system off my 90 camper for my syncro project. Probably everything external you would need to plumb a radiator on your van. PM me if there's something you need.
Should be a nice ride when you are done. Not easy to do a project and at the same time document it. Thank you. _________________ ☮️ |
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revolution337 Samba Member
Joined: May 23, 2009 Posts: 372 Location: Pennsylvania
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Posted: Sat Oct 13, 2018 6:29 pm Post subject: Re: My air-cooled to 1.8t build |
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MarkWard wrote: |
Shameless plug, but I stripped the cooling system off my 90 camper for my syncro project. Probably everything external you would need to plumb a radiator on your van. PM me if there's something you need.
Should be a nice ride when you are done. Not easy to do a project and at the same time document it. Thank you. |
Awesome, thanks for the heads up! There are still a few pieces that I need to acquire yet. Perhaps I'll message you if I can't come up with the parts locally. |
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AZ Landshaper Samba Member
Joined: February 08, 2009 Posts: 1698 Location: The Old Pueblo
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Posted: Sat Oct 13, 2018 9:03 pm Post subject: Re: My air-cooled to 1.8t build |
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Nothing is quite as satisfying as replacing an aircooled pancake engine w something more powerful and water cooled. I wish you many happy miles behind the wheel. _________________ Support Small Business.
-------------------------------------------------------
85 Weekender w/ EJ22
Previously
64, 71, 72, 73, 76, 81, 84, 85 & 87 Campmobiles and Westfalias
and a 67 bug. |
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TequilaSunSet Samba Member
Joined: May 30, 2012 Posts: 2109 Location: Philippines
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Posted: Sat Oct 13, 2018 10:05 pm Post subject: Re: My air-cooled to 1.8t build |
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Nice choice, best wishes in this adventure! _________________ Don't harsh my mellow...
1985 Hightower Vanagon 1.8T- Gone
1972 Panel Bus- Gone
1967 Bug- Gone
1964 Euro Sunroof Bug- Gone
1969/72/63 Sunroof Bug- Gone
1975 Brazilian Bug in the Philippines 🇵🇭- New to me |
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kublerwagen Samba Member
Joined: February 28, 2012 Posts: 104 Location: Portland, OR
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Posted: Sun Oct 14, 2018 7:40 am Post subject: Re: My air-cooled to 1.8t build |
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Are you going reverse rotation and using the Passat transmission? |
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revolution337 Samba Member
Joined: May 23, 2009 Posts: 372 Location: Pennsylvania
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Posted: Sun Oct 14, 2018 9:38 am Post subject: Re: My air-cooled to 1.8t build |
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kublerwagen wrote: |
Are you going reverse rotation and using the Passat transmission? |
No, just a KEP adapter and running factory 4 speed aircooled trans. |
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Vanagon Nut Samba Member
Joined: February 08, 2008 Posts: 10361 Location: Sunshine Coast B.C.
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Posted: Sun Oct 14, 2018 11:17 am Post subject: Re: My air-cooled to 1.8t build |
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revolution337 wrote: |
In regards to the long coolant lines, I'm undecided at this point which route I will be taking. I've read about numerous people running the long lengths of marine grade rubber hose without any issue. Most of what I would consider to be "quality hose" is pretty pricey though. I did a rough calculation and it would cost about the same as purchasing the SS lines. I still have some time to figure out which option will work best for me. |
Ya, probably a "wash" in terms of price.
You've obviously done your research but FWIW, if I ever did another air to water cooled swap, I'd build or source simple brackets to support the upper end of rad VS removing-installing the OE upper rad support from a donor.
Neil. _________________ 1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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danfromsyr Samba Member
Joined: March 01, 2004 Posts: 15141 Location: Syracuse, NY
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Posted: Sun Oct 14, 2018 2:57 pm Post subject: Re: My air-cooled to 1.8t build |
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Sub'd
I've been running a aircooled to H2o swap for over a decade and the last 4-5 years as an AEB 1.8t.
feel free to ask or PM me any questions.
the upper of my radiator is just pushed up into foam&rubber with a zip tie to keep it from rocking.
alls good. _________________
Abscate wrote: |
These are the reasons we have words like “wanker” |
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kublerwagen Samba Member
Joined: February 28, 2012 Posts: 104 Location: Portland, OR
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Posted: Sun Oct 14, 2018 4:07 pm Post subject: Re: My air-cooled to 1.8t build |
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That’s what we did for mine (Aircooled to ABA). Used a Dodge Ram radiator as it was cheaper and has a cap. It did block 5)3 spare tire space, but will be building a swing away for the rear bumper.
Edit - we built simple mounts. |
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dabaron Samba Member
Joined: June 21, 2018 Posts: 2559 Location: Philly, mang
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Posted: Sun Oct 14, 2018 5:30 pm Post subject: Re: My air-cooled to 1.8t build |
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if you are in the Philly area and need a hand let me know, this looks really interesting. _________________ 1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
BiWerks Design, LLC |
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revolution337 Samba Member
Joined: May 23, 2009 Posts: 372 Location: Pennsylvania
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Posted: Sun Oct 14, 2018 6:07 pm Post subject: Re: My air-cooled to 1.8t build |
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danfromsyr wrote: |
Sub'd
I've been running a aircooled to H2o swap for over a decade and the last 4-5 years as an AEB 1.8t.
feel free to ask or PM me any questions.
the upper of my radiator is just pushed up into foam&rubber with a zip tie to keep it from rocking.
alls good. |
Good to know. I've read almost all of the 1.8t threads on here from start to finish, and I recall seeing you post in several of them.
What did you end up using for an engine support bar/mounting? Also, did you space the transmission mount down at all? I've noticed others have done so and I'm not quite certain the pros/cons in doing so. Is it necessary in order to prevent too much of the engine sticking up above the deck lid?
dabaron wrote: |
if you are in the Philly area and need a hand let me know, this looks really interesting. |
I'm closer to Harrisburg, but thanks though! |
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danfromsyr Samba Member
Joined: March 01, 2004 Posts: 15141 Location: Syracuse, NY
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Posted: Sun Oct 14, 2018 6:25 pm Post subject: Re: My air-cooled to 1.8t build |
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on mine I modified a vanagon mustache bar and did not lower the trans mount.
my engine lid is raised 1inch (only in the center). _________________
Abscate wrote: |
These are the reasons we have words like “wanker” |
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Bills85Westy Samba Member
Joined: August 01, 2009 Posts: 423 Location: Napa CA
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Posted: Sun Oct 14, 2018 6:26 pm Post subject: Re: My air-cooled to 1.8t build |
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Looking forward to following your conversion! I know what it’s like to get attached to one van.
Following your thread!
Bill _________________ 89 Tristar Syncro Doka - White
85 Westfalia Syncro (conversion)
SAH 1.8T Conversion - 2005 AWP
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L |
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revolution337 Samba Member
Joined: May 23, 2009 Posts: 372 Location: Pennsylvania
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Posted: Sun Oct 14, 2018 6:51 pm Post subject: Re: My air-cooled to 1.8t build |
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danfromsyr wrote: |
on mine I modified a vanagon mustache bar and did not lower the trans mount.
my engine lid is raised 1inch (only in the center). |
Got it. I think the few people who lowered the trans mount were using a different transmission, or possibly syncro vehicles/conversions. |
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xoo00oox Samba Member
Joined: February 11, 2010 Posts: 2672 Location: East Nassau, NY
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Posted: Mon Oct 15, 2018 7:02 am Post subject: Re: My air-cooled to 1.8t build |
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Link
*EDIT- found a still picture....
As I mentioned in answering your PM, Here is an air-cooled van I converted to 1.8t. This one has the stock transmission spaced back about 2" It gives you a good amount of clearance of the coolant flange as you can see about 3 seconds into the video. Also check out the raised deck-lid I we make for the campers. It not only raises the lid, it also off-sets it so you can easily lift it up without having to slide it out from under the cabinet.
I have a really nice tune for the AEB ECM that works great in the vans if you are interested.
Andrew-
Good luck with your project! |
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revolution337 Samba Member
Joined: May 23, 2009 Posts: 372 Location: Pennsylvania
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Posted: Mon Oct 15, 2018 7:11 am Post subject: Re: My air-cooled to 1.8t build |
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xoo00oox wrote: |
*EDIT- found a still picture....
As I mentioned in answering your PM, Here is an air-cooled van I converted to 1.8t. This one has the stock transmission spaced back about 2" It gives you a good amount of clearance of the coolant flange as you can see about 3 seconds into the video. Also check out the raised deck-lid I we make for the campers. It not only raises the lid, it also off-sets it so you can easily lift it up without having to slide it out from under the cabinet.
I have a really nice tune for the AEB ECM that works great in the vans if you are interested.
Andrew-
Good luck with your project! |
I love your idea of making the raised deck lid spacer to go around the westy rear cabinet. I was dreading having to cut into the cabinet in order to fit other engine deck lid spacers. I will definitely be in touch with you regarding the tune and deck lid once I'm further along with the project. |
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