1986 Inline Gas Vanagon Conversion

[rmcd]

Kendalwoolf. What is the idea behind the front core shutoff valve?
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[nemobuscaptain]

I think I can answer this. That's a pretty common mod, not related to a swap. It keeps your feet from getting hot in the summer.
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[kendalwoolf]

[Vanagon Nut]

Cool. Thanks. Totally makes sense. Given your alternator post, was thinking ahead to crossover intake height of ABA, engine at 50º. All moot though.

Neil.

[metropoj]

And I guess for my sake not planning or having A/C in the van from stock I can push the alt over to where the Compressor lies and not need the mod to the deck.

[danfromsyr]

just make sure you get enough contact/wrap on the H2o pump.
they don't need 'just enough' they need 'plenty adequate' to keep the pump spinning in the rain
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[MarkWard]

My accelerator cable is solved. No pictures though. I pulled the vanagon cable out completely. I cut the engine end off and removed the cable from the sheath. I then removed the engine end of the sheath so there was just the conduit.

I took a used cable from an 86 golf that had the correct end and cut the pedal end of the cable off and removed the firewall grommet piece so that I ended up with two bare cable conduits. The length was perfect. I took a piece of heat shrink and connected the two conduits. I then slid a piece of 1/4 inch fuel hose over the conduit splice to reinforce the joint.

I went to HD and bought 20 feet of 1/16th cable. More than enough. I installed that with my modified conduit into the van. At the engine end, I cut about 4 inches off of the Golf's cable and attached that to the throttle body. In the lathe, I made a small aluminum sleeve with two set screws opposite each other. The sleeve was drilled to accommodate two cables. One from the throttle body and the new cable I installed into the van.

I secured the set screws with the cable ends passing each other and then moved up front. I tested and there is enough bolt length in the cable clamp to bare down on the cable and secure it without a finished end. I did add a washer to the pivot, so the cable does not ride against the pedal linkage. Pulled the cable tight secured it and reinstalled the cover.

Works great. No fancy brackets and no big bucks. I should have taken pictures, but time is limited and I need to work when I have time. I finally drove the van for the first time around the block. Unfortunately it was running on only 3 cylinders. Compression is good, plug wires are good. I pulled the injectors and sure enough one wire was broken. Whew.

Thank you for the help with the cable. mark
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[danfromsyr]

very cool

just an FYI, that after years of varying success on a multitude of engine swaps our current Throttle cable setup is to use a length (~12ft) of teflon lined bicycle cable housing with a small (think 7 strand) SS. marine (smallest they have actually) cable and the rubber bike cable 'noodles' to protect the ends from stuff.
I have a small asst kit for making the ends as needed but the most common is to crimp the barrel of a disassembled aluminum rivet to the cable to secure the ends.
I'll be tackling that this week on my 1.8T swap, I'll be sure to take some pics.
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[MarkWard]

I like the idea of a rivet. Smart thinking. I don't think crushing the braided cable is really the best way to do this, but all of this is temporary stuff. Found injector harnesses on fleebay for under $10 shipped to my door. I'll clean the injectors while I have them out.
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[winddude]

[denwood]

Kendal, with regard to the alternator poking through the engine, lid, my solution to that was as follows:

I used a GM alternator that is rated at 100 amps as the Bosch was too big to fit without modifiying the deck lid. I suspect this was a result of installing the AC in the configuration I did. The GM alternator is quite compact. Surprisingly, the alternator fit with a few washers to space it properly. The Bosch pulley was a direct replacement for the GM unit. The Alt light stayed on using this alternator until a switched 12 volt lead was added to the GM wire equivalent to the VW alternator warning light.

This has worked very nicely for the last nine years flawlessly...and for the new owner's drive to Edmonton (1200 miles)

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Cheers,
Dennis Wood
The Grape

[kendalwoolf]

[Richard Feliciano]

I have 1987 Vanagon-Camper with automatic transmission. I change to enginee Jetta2.0 with adapter plate (Ken-Co). I need the flywheel to finish.

[Richard Feliciano]

I have 1987 Vanagon-Camper with automatic transmission. I change to enginee Jetta2.0 with adapter plate (Ken-Co). I need the flywheel to finish.

[Richard Feliciano]

I have 1987 Vanagon-Camper with automatic transmission. I change to enginee Jetta2.0 with adapter plate (Ken-Co). I need the flywheel to finish.

[Richard Feliciano]

I have 1987 Vanagon-Camper with automatic transmission. I change to enginee Jetta2.0 with adapter plate (Ken-Co). I need the flywheel to finish.

[danfromsyr]

you need a FLEXPLATE to mate the adapter plate to your automatic transmission torque converter.

contact KEnnedy engineering for a 'replacement' flexplate.
http://www.kennedyenginc.com/Pages/default.aspx

KENNEDY ENGINEERED PRODUCTS

38822 17th Street East
Palmdale, California, 93550
Phone (661) 272–1147
Fax (661) 272-1575
email: [email protected]
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[kendalwoolf]

Just an update on the Inline Vanagon.
Had a small leaking head gasket on the the 1.8 engine and decided it was time to move forward with the 2.0 block and 1.8 head swap. One determining factor was when i blew the muffler up with a backfire as a result of a fouled spark plug from the head gasket leak. The pictures below show the muffler damage and the engine removal and build of the new 1.8 head on 2.0 block. Also installed a hotter cam, it was a used Techtonics 260* hydro cam. The idle on the startup and initial run was a little rough but I will need to see if it is the cam or the fact I had no exhaust on the van.
More Pictures and Videos to follow once I get it back from the muffler shop.

Muffler Issue

Engine Removal

1.8 Engine Out

1.8 Engine

Dirty 2.0 ABA Engine, only 60,000 miles on it.

Clean 1.8 Head

1.8 Head on 2.0 Block

Looking more like an Engine

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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

[tristessa]

Will the ABA distributor work with the existing FI system? I needed an adapter from Techtonics when I swapped to an ABA block, but that was with CIS and a mechanical+vacuum distributor .. and I know Digifart has ECU-controlled ignition advance.

Looking good!

[kendalwoolf]