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r39o
Samba Polizei
Joined: May 18, 2005
Posts: 9800
Location: San Diego
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 Posted: Fri May 30, 2008 12:35 am Post subject: |
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That manifold and those clamps bring back bad memories. Can you even get the tool in there to take the clamps off?
_________________
"Use the SEARCH, Luke" But first visit the Vanagon FAQ!
1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....
Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently) |
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nealcapener
Samba Member
Joined: November 12, 2005
Posts: 48
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| Posted: Mon Jun 02, 2008 7:05 am Post subject: |
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Is the starter a issue with the I4 in a syncro???
Neal |
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jensjakob
Samba Member
Joined: April 01, 2006
Posts: 94
Location: Denmark, Europe
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| Posted: Sat Jan 10, 2009 1:14 pm Post subject: |
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Hi,
I've just got myself a Vanagon with a Golf III 1.8I engine, gasoline, (1995 ABS).
I am wondering - in the enginebay there is only 1 expansion-tank, and no over-flow tank behind the service-flap.
To me it looks like the whole system is under quite high pressure when warm - compared to the standard WBX setup.
Does anyone have pictures of their setup with expansiontank-overflowtank or just expansiontank?
Happy driving
Jens Jakob |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10379
Location: Sunshine Coast B.C.
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| Posted: Sat Jan 10, 2009 1:41 pm Post subject: |
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All the gas I4 VW engines in Vanagons I've seen, only have the one expansion tank. As does my conversion.
I think the extra tank on the WBX is there for "convenience" (easier access and AFAIK, not under pressure when engine up to temp)
(note: these are not the latest pics.... there have been mods made since then.... but coolant tank is the same)
Neil.
_________________
1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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regis101
Samba Member
Joined: July 28, 2005
Posts: 2078
Location: Livermore, Ca
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| Posted: Sat Jan 10, 2009 2:29 pm Post subject: |
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Neil. Is the engine installed at the factory slant or more to fit the way it does. Thanks,
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Peace, Regis |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10379
Location: Sunshine Coast B.C.
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| Posted: Sat Jan 10, 2009 3:14 pm Post subject: |
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No.
This is a 15* DIY install. Much more "upright" than the factory install of the DV engine.
_________________
1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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jensjakob
Samba Member
Joined: April 01, 2006
Posts: 94
Location: Denmark, Europe
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| Posted: Sat Jan 10, 2009 4:19 pm Post subject: |
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| Vanagon Nut wrote: |
All the gas I4 VW engines in Vanagons I've seen, only have the one expansion tank. As does my conversion.
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Hi,
Great picture, thank you.
Where does the thin "overflow" pipe go from the top of your expansiontank?
As I have the stock "vanagon" expansion tank in my engine-bay, without the overflow-cap - I do not have that thin pipe.
Another question: What about oerpressure protection?
I know that on the Golf III - there is a 1.5 bar security valve in the cap on the front radiator - in an I4 conversion - where does overpressure go?
Happy driving
Jens Jakob
_________________
http://www.t3nettet.dk
Telebus: 1985 Vanagon, 1.9 DG engine, 4 gear
Ms Grey: 1983 Vanagon, Golf III 1995 1.8i 9hp engine - 5 gear |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10379
Location: Sunshine Coast B.C.
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| Posted: Sat Jan 10, 2009 7:03 pm Post subject: |
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| jensjakob wrote: |
| Vanagon Nut wrote: |
All the gas I4 VW engines in Vanagons I've seen, only have the one expansion tank. As does my conversion.
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Hi,
Great picture, thank you.
Where does the thin "overflow" pipe go from the top of your expansiontank?
As I have the stock "vanagon" expansion tank in my engine-bay, without the overflow-cap - I do not have that thin pipe.
Another question: What about oerpressure protection?
I know that on the Golf III - there is a 1.5 bar security valve in the cap on the front radiator - in an I4 conversion - where does overpressure go?
Happy driving
Jens Jakob |
The thin hose goes to the head. Coolant flows through this hose into the tank. So it isn't an "overflow" hose.  I don't have the WBX cooling system diagram handy, but I'm pretty sure the Jetta cooling system is somewhat different in terms of coolant flow/path. I "look at" my conversion (more or less) as a Jetta engine/cooling system in a Vanagon.
Overflow protection? Good question. One I thought of after most of the conversion was done  AFAIK, the valve on the cap of the expansion tank should suffice.
And I should clarify what I wrote:
"All the gas I4 VW engines in Vanagons I've seen, only have the one expansion tank. As does my conversion."
Should read:
"All the gas I4 VW engine *conversions* in Vanagons I've seen, ...... "
_________________
1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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r39o
Samba Polizei
Joined: May 18, 2005
Posts: 9800
Location: San Diego
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| Posted: Sat Jan 10, 2009 10:36 pm Post subject: |
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The little hose on all I4s from the late 70's to now all go to the upper radiator hose, typically at the radiator.
It is for coolant recovery and system air bleeding. These two tasks on the wbx are somewhat different. Bleeding is a royal pita in the stock wbx, as we well know. The wbx recovery is via the special cap. Maybe if you use an early tank with the same threads as a wbx, you could still use the wbx recovery system.
Sorry I don't know more. I was close to an I4 conversion myself, I have a 2L 16V and also an Audi 2L 8V engine, lots of I4 parts and knowledge from A series car engine swaps, but I am going Suby. I got the engine and parts are piling up. This thread just reminds me I still am not totally Suby but there are a few things that tilted the scales for me.....
_________________
"Use the SEARCH, Luke" But first visit the Vanagon FAQ!
1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....
Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently) |
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morymob
Samba Member
Joined: November 09, 2007
Posts: 4683
Location: east-tn
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| Posted: Sun Jan 11, 2009 6:41 am Post subject: |
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| I have surfed thru many posts the past couple yrs on engine swaps etc.O all the things involve with changes(brands),costs and mostly the history of the ones i have owned i will stick with my 1.9. Its a long time driver(13 yrs) and mucho miles (320k+now). I have tweeked it probably to the max and ave 24-25on road kept around 65,mymax. A 84-GL 4-sp.195/75/14 tires and checked many times on trips i make of 500+miles visiting kids. Checked with other vehicles but my favorite stillold Blue. Has plenty pep and no one waits on me either,so my 2cts on a tough,hard to beat"old" tech engine,my wifes new Honda CR-V has big shoes to fill. |
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jensjakob
Samba Member
Joined: April 01, 2006
Posts: 94
Location: Denmark, Europe
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| Posted: Sun Jan 11, 2009 2:09 pm Post subject: |
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Hi,
I have wrapped my head around the towel, and re-analyzed.
On the Vanagon original setup - the reason that we have the overflow tank at the service plate - is that is should be easy to check the water level.
So basically - on the Vanagon - the overflow tank behind the serviceplate _is_ the expansion tank.
And the reason that the resoirvoir-tank in the engine-bay is filled to the brim, is that it is basically that -a resoirvoir.
So I understand that on the VW I4 engines, the expansion-tank and resoirvoirtank is the one and same thing.
When the engine is cold, fluid should be toppe to the max-mark.
When driving - well, fluid will expand and compress the air - thus it should rise above max-mark -if radiator is properly bleed?
If there are too much air in the expansion-tank - could be blown gasket blowing air into the system - and it cant escape?
But, a blown gasket - should allways be seen on the exhaust -or could there be a blowngaskett, without water in the oil, and without water in the exhaust?
Best regards
Jens Jakob
_________________
http://www.t3nettet.dk
Telebus: 1985 Vanagon, 1.9 DG engine, 4 gear
Ms Grey: 1983 Vanagon, Golf III 1995 1.8i 9hp engine - 5 gear |
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boardrider247
Samba Member
Joined: January 23, 2006
Posts: 19
Location: Forest Lake, MN
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| Posted: Mon Feb 23, 2009 8:09 am Post subject: |
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| ebennett wrote: |
I am coming down the home stretch here with my Vanagon conversion. I'm using a 2.0L bottom end with a 1.8L head and digifant FI
A special thanks to Bill W!
I've used all VW parts. Here is a list of diesel vanagon parts that I used;
trans bell housing
trans input shaft
clutch, pressure plate, throw out bearing
flywheel
starter motor * hard to find
motor mounts
engine carrier bars
diesel coolant hoses * hard to find, check ebay
diesel coolant bottles
diesel oil pan and fill tube
diesel oil pump pick up tube
1992 Jetta A2 parts
Complete Cylinder Head
wire harness
intake manifold with throttle body
toilet bowl exhaust manifold & down pipe
all sensors, air, temp,
1996 Jetta (early OBD1 blocks are the best!)
Bottom end of engine 2.0L ABA
distributor
alternator
timing belt and tensioner
AC compressor
water pump
all belts and pulleys
So far the only custom mod I have needed is an exhaust.
I hope to have the electrical finished this weekend and be up and running by the end of this month.
i can't afford to have autobahn society to do the work for me so I have to do it myself |
So just to clarify. You are using a diesel bellhousing on the waterboxxer transmission? For some reason I thought I had read before that this wouldn't work. But if it does thats great news. |
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?Waldo?
Samba Member
Joined: February 22, 2006
Posts: 9752
Location: Where?
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| Posted: Mon Feb 23, 2009 9:10 am Post subject: |
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My inline-4 gas has the stock diesel hoses and two tanks, the stock vanagon expansion tank and the overflow tank.
Andrew |
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oasis
Samba Member
Joined: December 12, 2002
Posts: 2168
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| Posted: Tue Apr 05, 2011 9:31 am Post subject: |
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Before some jackass tells me to search again which I did the first time and several times as a matter of fact, let me state my particular situation and what basics I need to know and/or get.
I do not want to debate the merits of one conversion over another. I am not a DIY'er. I have a VW-specialty shop willing to do the work. I have a '97 Jetta with an ABA engine. That is the engine I want to eventually use.
What are the basic parts or source I need for this conversion?
Is there a best year(s) Vanagon I should look to buy or years (besides air-cooled and diesels) I should avoid?
My searches have given me hundreds of threads of endless debates over other conversions, great ideas by DIY'ers, etc. I can narrow my searches to specifics once I know the basics. Reading the specifics is worthless to me at this stage, and hundreds of threads talking about specifics is a waste of time.
_________________
Now: 2003 New Beetle Turbo S / 1990 Single Cab Transporter / 2014 Tiguan R-Line 4motion / 2013 Tiguan S / 2002 Golf GLS TDI
Past: 1974 Thing Acapulco / 2009 Eos Komfort / 1997 Jetta GT / 2002 Cabrio GLX / 2002 Passat GLS / 1971 Super Beetle / 1993 EuroVan MV Westfalia / 1981 Pickup LX / 1985 Vanagon / 1986 Jetta GLI |
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D Clymer
Samba Member
Joined: December 22, 2005
Posts: 2978
Location: Issaquah, WA
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| Posted: Tue Apr 05, 2011 10:01 am Post subject: |
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| oasis wrote: |
What are the basic parts or source I need for this conversion?
Is there a best year(s) Vanagon I should look to buy or years (besides air-cooled and diesels) I should avoid?
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To physically mount the engine you will need the carrier bars, bellhousing, and oil pan from a diesel Vanagon. The carrier bars should be from an 83 rather than an 82 diesel since they mount the engine in the right position for the later style wasserboxer transmission location.
If you are using the ABA 2.0 engine complete, the intake manifold will hit the engine bay lid and you will need to modify it. You can also swap a non-crossflow head (from a 1.8 ) onto the ABA and this will allow everything to stay below the lid. It will also keep the coolant hose configuration standard so that you can use diesel hoses with no modifications. The ABA head has the water inlet relocated to the side of the head from the front, and would require some hose reconfiguring.
As far as fuel injection - you can either run the engine with the correct ABA Bosch Motronic system, or you can make things simpler by running Digifant from a Golf or Jetta II 1.8. Digifant is easier to hook up, and has less components, but the Motronic is a far superior system - so I would go that route.
Vanagon Nut (Neil) can tell you alot about this conversion since has done one, drives one, and documents all his work. You might send him a PM to get his thoughts.
Nobody is excited about a 2.0 inline swap these days. 115hp and 121 torque are only moderate improvements over the wbx, but there is nothing wrong with this swap. The engines are durable, economical and easy to get. The exhaust tends to be the biggest area of trouble on these, and it needs to be custom made. So make sure you study what has worked and what hasn't worked with exhuast systems for this conversion.
David |
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Tank83
Samba Member
Joined: October 13, 2006
Posts: 115
Location: Germany - near Heilbronn
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| Posted: Tue Apr 05, 2011 10:22 am Post subject: |
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Hi there, we've just made a i4 conversion to my bus.
We used the AGG engine, it'a Golf 3 engine from 1995.
2.0 liter 8v 115hp.
This engine has a simos ecu & is obd compatible.
My bus was a diesel before, so we had nearly everything to make this conversion:
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oasis
Samba Member
Joined: December 12, 2002
Posts: 2168
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| Posted: Tue Apr 05, 2011 10:53 am Post subject: |
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Thanks for the responses, guys. I used to own an '85 Vanagon (1991-97) and loved it; eventually got a EuroVan poptop MV -- different animal, loved it, too. We have been without a vehicle of size for a few years and it has been annoying at times.
My wife is happy with her TDI Golf so that is out of the question since she doesn't want to upgrade to something newer. Selling my dad's Passat is something that will happen soon and the 1.8T would be a more potent offering, selling that car engine-less would be a harsh financial hit. We got the Jetta for our daughter because of the bulletproof-ness of the ABA, and can probably do okay parting out the Jetta's remains after that.
As for the pedestrian performance, I can live with that. We drove our '85 with its 1.9L round trip MD-to-FL twice plus other notable trips. The EuroVan was better for highway stuff, but was a bit lumbering around town. The ABA will be plenty powerful enough. I can get all of the speeding tickets I want with my Eos and my to-be-determined air-cooled car.
One repeat question: Does it matter which year Vanagon I am looking for?
One side question: Will the stock transaxle be fine? (I suppose a gearing upgrade can be looked into eventually, but I'm more on Step One so I'm necessarily looking into what's best ... yet.)
Thanks again.
_________________
Now: 2003 New Beetle Turbo S / 1990 Single Cab Transporter / 2014 Tiguan R-Line 4motion / 2013 Tiguan S / 2002 Golf GLS TDI
Past: 1974 Thing Acapulco / 2009 Eos Komfort / 1997 Jetta GT / 2002 Cabrio GLX / 2002 Passat GLS / 1971 Super Beetle / 1993 EuroVan MV Westfalia / 1981 Pickup LX / 1985 Vanagon / 1986 Jetta GLI |
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Tank83
Samba Member
Joined: October 13, 2006
Posts: 115
Location: Germany - near Heilbronn
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| Posted: Tue Apr 05, 2011 11:05 am Post subject: |
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| oasis wrote: |
One repeat question: Does it matter which year Vanagon I am looking for?
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Should be water cooled, air cooled to water cooled conversion is very hard.
If you want to convert to a i4 engine the best vanagon would be a diesel.
If you buy a boxer powered vanagon you will need to buy much parts to get a i4 fit into your bus.
| oasis wrote: |
One side question: Will the stock transaxle be fine? (I suppose a gearing upgrade can be looked into eventually, but I'm more on Step One so I'm necessarily looking into what's best ... yet.) |
For which engine? The 3h gearbox is fine for the 115hp i4 conversion by the agg, ady or 2e angine. |
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Zeitgeist 13
Samba Member
Joined: March 05, 2009
Posts: 12115
Location: Port Manteau
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| Posted: Tue Apr 05, 2011 11:06 am Post subject: |
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| D Clymer wrote: |
To physically mount the engine you will need the carrier bars, bellhousing, and oil pan from a diesel Vanagon. The carrier bars should be from an 83 rather than an 82 diesel since they mount the engine in the right position for the later style wasserboxer transmission location.
David |
Is there a handy tip so that one can easily tell if they've got the carrier bars from one year or the other? If one has the earlier bars, is there a standard modification that fixes that issue?
Thanks,
Casey
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Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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Captain Pike
Samba Member
Joined: December 30, 2003
Posts: 3343
Location: Talos IV, Piedmont Arizona
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| Posted: Tue Apr 05, 2011 11:38 am Post subject: |
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| Zeitgeist 13 wrote: |
| D Clymer wrote: |
To physically mount the engine you will need the carrier bars, bellhousing, and oil pan from a diesel Vanagon. The carrier bars should be from an 83 rather than an 82 diesel since they mount the engine in the right position for the later style wasserboxer transmission location.
David |
Is there a handy tip so that one can easily tell if they've got the carrier bars from one year or the other? If one has the earlier bars, is there a standard modification that fixes that issue?
Thanks,
Casey |
Easy way to get past that is to flip/modify the trans mount and cut 1 1/2 inch off the shift shaft.
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LEARN TO SELF RESCUE
59 Panel bus, 1966 Single cab. 73' 181. 73 Westy. 91' H6 Vanagon 3.3L.
.....................All Current....................... |
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