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1986 Inline Gas Vanagon Conversion
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kendalwoolf
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Joined: January 20, 2006
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Location: Fayette, MO
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PostPosted: Fri May 25, 2012 5:37 pm    Post subject: 1986 Inline Gas Vanagon Conversion Reply with quote

The Vanagon has been on the road for some months now so I thought it was time to make the build post.

The van was in poor shape when purchased. ALL the interior door panels, seats and carpet was spray painted blue. Thankfully over-spray was minimal and could be removed with paint thinner.
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I bought a used interior from a Samba member and made some "custom" carpet from a 6x8 foot indoor/outdoor carpet from Home Depot, using the old carpet as a pattern.

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Interior Done.
It is no show van but it makes a great Vacation/Camping van.
Next post will be Engine Conversion...
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-Kendal-
71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20
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goffoz
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PostPosted: Fri May 25, 2012 7:23 pm    Post subject: Reply with quote

Blue rattle can?? everywhere?...what kind of person thinks of that?
maybe a regular HGTV type.

Why is that there are so many people who just do the dumbest stuff to these vans Rolling Eyes

Your doing a great job Very Happy I really like the HD carpet method....I did the same thing except I used black marine vinyl flooring.
.....would have used rubber, but I can't find it over 48" Sad
Keep up the good work.
what conversion are you going for?
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kendalwoolf
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PostPosted: Fri May 25, 2012 7:26 pm    Post subject: Engine Conversion Reply with quote

The engine conversion is just the standard Jetta 1.8 Inline engine using diesel Vanagon parts. 1988 VW Jetta Digifant with Audi 4000s exhaust manifold.

Modifications:

Drivers side frame rail pushed in using a torch and slide hammer to allow clearance for intake manifold.

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I used the entire engine Jetta wiring harness and stock Vanagon fuel pump relay and ECU relay.

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Flipped the alternator to the other side of the AC compressor to clear the decklid (I will upgrade to an ABA 2.0 block with 1.8 head and serpentine belt sometime in the future, but the 1.8 is running great right now).

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First air intake was AFM air filter adaptor (Ebay Bestcarpart) and flexible 3 inch intake hose (www.stageonetuning.com) adapted with 2.75 inch silicone hose and adapter (www.siliconeintakes.com).

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Update to intake: Used Factory Vanagon air cleaner housing (with some trimming) on passenger side behind tail light.

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1.6 Diesel Vanagon muffler (Same muffler as the 1.9 WBX Vanagon engine except for one slip on connection and the Diesel mounts). Custom down pipe with glasspack and O2 sensor bung welded by Hilltop Muffler Oak Ridge TN.

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Front heater core shutoff inside the van using a ¾ inch ball valve from home improvement store.

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Tires: Nokian 195R 14 Hakkapeliitta CS from Van Café.

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Here is a list of some of the other parts used.

Coolant hose to radiator, hose #71386 (AutoZone) (Diesel Vanagon hose AutoZone 1106 62161).

Coolant expansion tank bracket (www.greaseworks.com).

Used Tiico throttle cable from thesamba member Escorial Syncro, Thanks.

Power steering connections 14 inches of hose from Jetta pump, Gates male flareless assembly 6G-6MFA, to High Pressure metal line at back of van, using Gates connector 6G-10MDL. Power steering is making a whining noise, possibly due to no restrictor in custom hose from Jetta pump to Vanagon PS line.

Air Conditioning: Flushed system, condenser and evaporator along with associated lines, with Air line dryer fluid purchased from NAPA, and charged with REDTEK.


Entire Picture album is here:
https://picasaweb.google.com/kendalwoolf/MyGasVanagonSwap?authuser=0&feat=directlink

I hope this helps some other Vanagon owners.
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-Kendal-
71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20
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kendalwoolf
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PostPosted: Fri May 25, 2012 7:32 pm    Post subject: Time lapse Reply with quote

This is more of a time lapse delay post.
The conversion is done and I have put around 6000 miles on it.
I am just slow about posting. I was having too much fun driving the van to take the time and type up the post.
I have no idea what made the previous owner paint the interior blue, but the damage was mostly to removable pieces which made it a lot easier to fix.

More to come later about gas tank replacement and custom curtains.
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-Kendal-
71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20
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geodude
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PostPosted: Fri May 25, 2012 10:11 pm    Post subject: Reply with quote

I converted my first Vanagon very similarly to yours and it gave me years of trouble free service. I started with a 1.8 (code RV?) with Cis-e injection. I had the fuel distributor / airmeter over in the driver side pillar area with a Volvo 240 casting on the bottom side so I could use a remote filter. The filter was over on the other side like yours. Started with the toilet bowl exhaust manifold but later changed to the audi dual downpipe from an audi 80 and it made a noticeable difference. My exhaust ran up ahead of the engine and doubled back, so a bit different then your setup. Drove that thing all over the country with barely a problem, I think you will have a good time with it.
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kendalwoolf
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PostPosted: Tue Jun 19, 2012 7:25 pm    Post subject: Gas Tank Replacement Reply with quote

I have been enjoying the engine conversion but had a small issue at the start of winter. (it has been a while now but I thought I would post just in case it helps others on the forum).

When it was cold outside, below 45F, the van would start and die a few times then idle OK but would not take any throttle or it would backfire through the intake and had no power, Until the engine warmed up, then power was OK, I could drive up hills but not enough to hold 55mph. After a lot of checking and part swapping with known good parts I found that the gas tank was full of rust and had plugged the filter and even worked its way to the injectors.
The reason it would run well once warm was the oxygen sensor would start working and compensate for the lean running condition of the plugged filter and injectors.
I have included few pictures of the tank and rust.

With the new tank, filter and other good used parts it was back to running great again. The moral of the story is to check your tank for rust, it can cause a lot of problems.

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This is the fine rust that made it past the filter, I think it ruptured the filter.

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_________________
-Kendal-
71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20
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kendalwoolf
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PostPosted: Tue Jun 19, 2012 7:40 pm    Post subject: Trip to Cades Cove, Smoky Mountains TN Reply with quote

With the Gas Tank issue fixed we took the Vanagon to the Great Smoky Mountains. We had a great trip. We camped and Vanagon sleep well. The bed if very comfortable.

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We made custom curtains for the van. At first we were going to use snaps to attach them but ended up using rare earth magnets. They work great, no holes the van and easy to put up and take down. We ordered the magnets from Leevalley http://www.leevalley.com/US/hardware/page.aspx?p=32065&cat=3,42363,42348&ap=1
1/2 inch diameter magnets, that are sewn into pockets in the fabric.
I can post more detailed info on the curtains if needed. Enjoy



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_________________
-Kendal-
71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20
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MidwestDrifter
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PostPosted: Wed Jun 20, 2012 6:29 am    Post subject: Reply with quote

Sweet van, Thanks for posting. Looks like a really clean swap.
You mention you flipped the alternator position. Did you have to modify the alternators mount to fit there? I am considering adding AC to my I4 swap in the future, so I am considering my options.
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buspor63
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PostPosted: Wed Jun 20, 2012 8:40 pm    Post subject: Reply with quote

Kendal,
You have been a busy guy with two Vanagon conversions going on at once, impressive. We should try to meet at Big Ed's for some pizza and Vanagon talk some day.
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devesvws
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PostPosted: Fri Jun 22, 2012 5:59 am    Post subject: Reply with quote

nice van Wink any idea what the mpg is?
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kendalwoolf
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PostPosted: Fri Jun 22, 2012 6:11 pm    Post subject: Reply with quote

MidwestDrifter:

When I flipped the alternator position I drilled through the AC mount to fit the pivot point or the alternator. I also had to heat and bent the adjuster mount for the top of the alternator.

You can see in the pictures some of the modifications I have marked with circles. Yellow circles indicate the pivot hole, red circles are the bent areas

You will have to go to the album to zoom in to see them up close they are the last 3 pictures.

https://picasaweb.google.com/kendalwoolf/MyGasVanagonSwap?authuser=0&feat=directlink

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The fan on the alternator does get close to the AC mount but using a longer alternator belt would solve this, I just kept the stock Jetta belt.
I hope this is helpful
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-Kendal-
71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20
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kendalwoolf
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PostPosted: Fri Jun 22, 2012 6:18 pm    Post subject: Reply with quote

buspor63 wrote:
Kendal,
You have been a busy guy with two Vanagon conversions going on at once, impressive. We should try to meet at Big Ed's for some pizza and Vanagon talk some day.


We should do that some time this summer. I have see your syncro post, very nice.
I have not been as busy as my posts seem to be because the Diesel conversion has been done for a few years now, I am just slow at posting. The main work lately has been on the Gas conversion.

Also my wife and I will be going to the Summer Jam in Townsend TN July 21-22.
http://www.summerjamvw.com/index.html
We could also meet up then if you are planning on attending.
_________________
-Kendal-
71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20


Last edited by kendalwoolf on Fri Jun 22, 2012 6:28 pm; edited 1 time in total
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kendalwoolf
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PostPosted: Fri Jun 22, 2012 6:23 pm    Post subject: Gas Mileage Reply with quote

devesvws wrote:
nice van Wink any idea what the mpg is?


Gas mileage has been 22 to 23 MPG. I will post what I get after our 4th of July trip which will be mostly interstate and AC on Full.
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71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20
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MidwestDrifter
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PostPosted: Fri Jun 22, 2012 7:44 pm    Post subject: Reply with quote

Thanks for the clarification on your alternator setup. Looks legit to me.
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kendalwoolf
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PostPosted: Fri Jul 13, 2012 6:19 am    Post subject: 4th of July MPG, interstate and A/C on Reply with quote

Update from the 4th of July trip. 1600 miles mostly 65-70mph interstate and A/C on 50% of the time, averaged 20 MPG.
Not bad for that speed and the A/C on.
Only one problem during the trip, the A/C belt broke and came off halfway back on the return trip. Replaced the belt with a spare I had under the seat and we were back on the road.
I believe I have a problem with the pulley on the A/C compressor, this is the second belt in a few thousand miles. It wears them very quickly at interstate speeds with the A/C on. I am just glad it was all working during the first half of the trip, when we left TN it was 104F, but with the A/C on it was very comfortable in the van. I will swap compressors and refill with RedTek and see if that fixes the problem.
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-Kendal-
71 VW Super Beetle, 74 VW Bus, 85 Jetta GLI, 89 Whitestar
86 Vanagon, 1.6TD http://www.thesamba.com/vw/forum/viewtopic.php?t=499268
86 Vanagon, 1.8 Digifant http://www.thesamba.com/vw/forum/viewtopic.php?t=513537
"but lay up for yourselves treasures in heaven, where neither moth nor rust destroys and where thieves do not break in and steal." Matthew 6:20
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KrisBalfe
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PostPosted: Tue Jul 17, 2012 9:10 am    Post subject: Reply with quote

I have this same conversion in my '85 glad to hear you are pleased with it mine was put in and given up on so I get to finish the work. May have to send some questions your way...
congrats
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danfromsyr
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PostPosted: Tue Jul 17, 2012 10:42 am    Post subject: Reply with quote

sounds like a good trip then.

I also just did ~1800mi fromthe 4th in our jetta 1.8l converted camper
I'm getting ~20mpg heavily loaded but my O2 isn't hooked up so I'm not adjusting fuel enrichment and likely running richer than should be.

Kudos and keep the good times and VWs rolling.
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Far_West
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PostPosted: Tue Jul 31, 2012 3:36 pm    Post subject: 2.0 ABA replacing 1.8 inline Reply with quote

I have an 87' Vanagon camper with a 1.8 jetta inline already installed but had an engine falsh, melted the wiring harness. How much work to replace with 2.0ABA engine? Different engine mounts? Adapter plate? I have a running donor car..97 jetta 2.0 ABA for the swap. What am I dealing with here?
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KDI_CUSTOMS
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PostPosted: Wed Aug 01, 2012 10:43 am    Post subject: Re: 2.0 ABA replacing 1.8 inline Reply with quote

Far_West wrote:
I have an 87' Vanagon camper with a 1.8 jetta inline already installed but had an engine falsh, melted the wiring harness. How much work to replace with 2.0ABA engine? Different engine mounts? Adapter plate? I have a running donor car..97 jetta 2.0 ABA for the swap. What am I dealing with here?


Im not an expert on this subject but if you already have the 1.8 installed, I believe it is a direct swap for the 2.0. I know the block is basically the same so Id assume it shouldnt be a problem.
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MidwestDrifter
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PostPosted: Wed Aug 01, 2012 11:32 am    Post subject: Reply with quote

The mounts and adapter plate/bellhousing will bolt right up to the ABA engine. You may need to re-use some of the cooling system parts to get everything back in.

If you use the 1.8l head you may need to do some cutting of the engine tin on the drivers side, as the ABA block is slightly taller.

If you use the Complete engine (head and block) you will need to raise your read decklid as the intake manifold will interfere.

I have never done it myself, but I have heard that the motronic engine management system that comes on the ABA is not terribly difficult to wire up.

You may need a spacer on the exhaust manifold to downpipe depending on how your exhaust is set up. Several vendors sell them for ABA swaps into Mk2 VW cars.
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2004 Dodge/Mercedes Sprinter (Custom Camper)
2000 Jetta TDI
1982 Diesel Westy W/ ABA I4 hybrid (Sold)
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