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Heart transplant: 2.1 WBX to FAS Gen V 2.0T
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Red Beard
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PostPosted: Wed Feb 21, 2018 3:59 pm    Post subject: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

The patient:
Image may have been reduced in size. Click image to view fullscreen.


That's my foot sticking out from underneath, during our spring road trip through Utah last year. Our 1990 AT 2.1 WBX had actually been quite reliable for us since we bought it, through many long trips and thousands of miles. This trip offered my first taste of emergency roadside repair--multiple times. In the case pictured, a loop of heater hose somehow had found its way down to the left CV boot, where the friction wore a weeping hole in it. A week prior I had diagnosed a harsh whine from the engine as an alternator dying, fixed outside a FLAPS in a little middle of nowhere town. A little later I noted a new oil leak--rear main seal, and was feeling paranoid about that the rest of the trip. I also discovered that at altitude, in the cold, the van didn't like to start, despite flawless performance near sea-level.

For years I've looked at engine conversion options, but hadn't pulled the trigger because the WBX seemed to be doing fine. But through those years, every trip we took, I was constantly monitoring every sound and vibration, stomach in a knot, awaiting a breakdown. This constant tension has been tiring, although perhaps it was good for abdominal muscle development.

I think of myself as pretty resilient and resourceful, able to deal with things like breakdowns when they arise. This confidence was gained largely through necessity, due to being broke and driving junky cars in my youth. But since adding a little kid to the mix (and another on the way,) and becoming not-so-broke, I've increasingly desired greater reliability. Yes, there is satisfaction to be had from solving a problem in a pinch, but I'd rather be spending my time on the road relaxed, enjoying the scenery and my family.

In addition to the breakdowns last spring, I have wanted to put a little more power to the wheels. When fully loaded, I found myself often topping out at 35mph in a 75mph zone, up high desert inclines or over mountain passes. I also found myself getting stuck in places due to not transferring enough low end torque to the rear (peloquin diff doesn't help much if you can't even get the wheels to spin.)

So, the goals for conversion were reliability first, followed by increased power. I looked at a bunch of options, and considered whether to hire the work out or do it myself. I won't completely hash out here how I ended up going this route, but the biggest factors where getting a factory new motor, all new components, a dialed conversion system, solid documentation, fantastic support for the install, and the promise of smooth and reliable power on completion. For those interested, in the kit I am using, check this link:

http://www.foreignautosupply.com/engine-and-drive-train-programs/gen-v/

I was able to chat a bit with others who have this conversion, and all reports were positive. However, I was not able to find anyone who had documented or reported on a DIY install, so I thought it would be nice to try and provide that for others who may be considering this option.
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1990 Vanagon, FAS Gen V 2.0 NA, AT w/ Peloquin diff, NAHT conversion
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oceanair
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PostPosted: Wed Feb 21, 2018 4:50 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Fantastic -- looking forward to your journey -- that's the option I'm going to take sooner rather than later. Looks like an excellent option.
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regis101
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PostPosted: Wed Feb 21, 2018 6:00 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Lots of volks will be looking over this thread .
Maybe try to do a before and after 30-50 test for yourself.
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MarkWard
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PostPosted: Wed Feb 21, 2018 6:20 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

You will still have tension, just one less thing to worry about. It's the nature of driving antiques cross country. FAS seems to have done their homework.
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Red Beard
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PostPosted: Thu Feb 22, 2018 2:45 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

regis101 wrote:
Lots of volks will be looking over this thread .
Maybe try to do a before and after 30-50 test for yourself.


Too late--dropped the WBX already Laughing But this video from someone else should be informative:


Link


Quote:
This is a turbocharged 2.0 gen 5 engine from foreign auto supply. It can rip a fully loaded Westfalia camper from 0 to 60 in about 10 seconds when I looked down and called it out it was easily 62-63. This is the fastest vanagon I've ever driven and yes I've driven the bastardized vanaru.


Now, he says 10 seconds, but it looks to me that's on a little bit of a downhill. Nevertheless, its obviously fast.
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1990 Vanagon, FAS Gen V 2.0 NA, AT w/ Peloquin diff, NAHT conversion


Last edited by Red Beard on Thu Feb 22, 2018 3:17 pm; edited 1 time in total
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Red Beard
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PostPosted: Thu Feb 22, 2018 2:56 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Preparation:

I had initially contacted Jon at FAS last spring to talk about their conversion program. He was very down to earth, and very giving of his time. He offered to send me an electronic copy of the installation manual so that I might get an idea what a DIY install would look like. The manual was clear, and he was happy to answer some questions I had about the process even though I hadn't made a commitment.

Over the last many months, I looked at other options, but ultimately settled on this kit. Several more calls and emails with questions were answered kindly and promptly. I was initially going to go with the 2.0 NA option, but after considering the upfront cost of the turbo kit vs. cost of converting to turbo down the road, and input from folks here, I opted to spend a little more and do the turbo up front.

I paid the deposit mid January this year, planning to do the install during some time off from work in February. Unfortunately, a bunch of other people purchased turbo kits at the same time, and they ran out of turbo wastegates before building my engine, which ended up being backordered several weeks. While disappointing, communication on this was good, and I did get some teaser photos of my engine awaiting the missing part:


Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


In order to get some of the work done before I had to return to my job, Jon offered to send out a mini-kit containing some bracketry, wiring harnesses, and other parts so that I could get started. Usually, everything would show up at once in a big beautiful crate, ready to go. I appreciated the offer and took him up on it.[/img]
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Red Beard
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PostPosted: Thu Feb 22, 2018 3:13 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Day 1: Removing WBX

I won't lie, I felt sort of guilty and indulgent removing a perfectly good engine from this van. While I had done quite a bit of amateur mechanic work for myself in the past, this was by far the biggest procedure I had ever tackled.

Parting shot:
Image may have been reduced in size. Click image to view fullscreen.


I took a video of it running, with the goal of selling the engine once out.

Everything went pretty quick, the hardest part was getting the van up on blocks so I'd have room to pull it out.

Image may have been reduced in size. Click image to view fullscreen.


I had picked up a hoist from Harbor Freight for about $90, on sale, and I'll just sell it once this is done.

Image may have been reduced in size. Click image to view fullscreen.


Obligatory 'standing in the engine bay' shot:

Image may have been reduced in size. Click image to view fullscreen.


I had actually budgeted the whole weekend to do this, but it only took about 4 hrs until the engine and transmission were on the ground in my carport, and the transmission separated. I pulled the torque converter and discovered a bellhousing full of crud--old oil and dirt from the rear main seal leak that had developed last spring.

Image may have been reduced in size. Click image to view fullscreen.


This transmission was rebuilt about 15k miles ago, and the TC seal looked fine, but I will replace it anyway. I carefully cleaned the bellhousing and the back side of the torque converter, and set the whole assembly aside.

Image may have been reduced in size. Click image to view fullscreen.


I had stainless coolant pipes from Van Cafe sitting in storage, so I decided to use the rest of the day to install those. I lowered the gas tank about 2 inches, cut the old plastic pipes in half, and pulled them out. I double and triple checked the orientation of the pipes I was removing, making sure to slide the corresponding steel pipes into the right spots. Its true that, at least with these split SS pipes, you do not need to completely remove the tank to get them in. Just slide them and twist them into place.

Time: 8 hours
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Last edited by Red Beard on Thu Feb 22, 2018 3:42 pm; edited 1 time in total
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Vanagon Nut
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PostPosted: Thu Feb 22, 2018 3:28 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Nice to see the process starting and always good to see engine "porn".

Looking forward to see how it all goes in.

Thanks

Neil.
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AZ Landshaper
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PostPosted: Thu Feb 22, 2018 3:30 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Looks like fun man. What kind of blocks is your van on? Looks like cinder blocks.
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Red Beard
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PostPosted: Thu Feb 22, 2018 3:41 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Day 2: Redo coolant pipes, clean and prep

The night after removing the WBX, I laid in bed reading Bentley. Exciting. While reading, I got a funny feeling that I had somehow managed to install those coolant pipes totally backwards, despite being extra careful. Couldn't sleep until I checked it out, so I threw on a coat and went to look, sure enough, I had them switched side-to-side. Mad So first thing the next morning I lowered the gas tank, uninstalled, and reinstalled the pipes.

Following that, I went to work prepping the engine compartment. Did a cursory cleaning.

Image may have been reduced in size. Click image to view fullscreen.


Next, in preparation for the new carrier bar, I had to remove a small spacer plate welded on the outside of the passenger frame rail. In my case, this plate was welded along the front and rear edges. Apparently, this little plate is usually spot welded on, and you would drill those welds then pry the plate off with a chisel. A little work with the grinder and it was gone.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


In the second pic, you can see the little crescent shaped cut out on the bottom of the frame rail. The manual suggests additional clearancing with the grinder, toward the front of the car. You can see the small bit of clearancing I did in the pic.

For the turbo install, the intercooler will install toward the rear of the engine compartment on the passenger side, so the original power steering reservoir bracket must be removed. More grinding.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Cleaned, primed, and painted those ground spots.

In the following pic, the WBX engine harness has been unplugged from the J box and removed. The stock taillight harness and J-box to dash harness are reused. New wiring will plug directly into these connectors, no need to cut and splice anything.

Image may have been reduced in size. Click image to view fullscreen.


This harness to the fuel pump can be reused, but I will replace with a new harness that FAS will supply. "While I am in here..."

Image may have been reduced in size. Click image to view fullscreen.


Time today: 4 hrs
Total time: 12hrs
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Red Beard
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PostPosted: Thu Feb 22, 2018 3:52 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

AZ Landshaper wrote:
Looks like fun man. What kind of blocks is your van on? Looks like cinder blocks.


There are also jack stands, just can't see them in the pic.
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Zeitgeist 13
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PostPosted: Thu Feb 22, 2018 4:03 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Red Beard wrote:
Day 1: Removing WBX

I won't lie, I felt sort of guilty and indulgent removing a perfectly good engine from this van.


Yep, I also pulled a perfectly cromulent engine apparently for no decent reason. I picked up my kids and then parked the van and did the vicious deed in that non-offensive resting position...and now the van hasn't run in well over a year. That's pretty dumb. Hopefully buying a complete kit makes this a much simpler and more timely start to finish project for you.
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PostPosted: Thu Feb 22, 2018 4:07 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Red Beard wrote:
There are also jack stands, just can't see them in the pic.


Are you referring to the jack stands shown off to the side of the van? There's no shadow of anything in front of the rear tires supporting the van on the driver's side, all the way up to the shadow of the jack stands that are not under the van.

Image may have been reduced in size. Click image to view fullscreen.


It looks like you have the cinder blocks turned the stronger way, but either way they should not be used to support a vehicle, especially one as heavy as a Vanagon.
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PostPosted: Thu Feb 22, 2018 4:19 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Great call. You won’t be disappointed with the FAS conversion. I went for a ride in Jon’s converted syncro with 2.0 turbo and it absolutely rips. They offer amazing support and back up their products 100%. I’ll definitely be following this thread. Good luck and enjoy. Thanks for sharing the process.
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Red Beard
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PostPosted: Thu Feb 22, 2018 4:54 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

?Waldo? wrote:
Red Beard wrote:
There are also jack stands, just can't see them in the pic.


Are you referring to the jack stands shown off to the side of the van? There's no shadow of anything in front of the rear tires supporting the van on the driver's side, all the way up to the shadow of the jack stands that are not under the van.

It looks like you have the cinder blocks turned the stronger way, but either way they should not be used to support a vehicle, especially one as heavy as a Vanagon.


No, those 3 ton jack stands were too short, and I ended up having to buy some 24" tall 6 ton stands at Harbor Freight (fortunately, close by) to be able to reach.
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Red Beard
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PostPosted: Thu Feb 22, 2018 5:21 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Interlude:

Got a box today. These parts would normally all come in the big crate with the engine, but I got this mini-kit so that I could get some work done during available time off from work.

Image may have been reduced in size. Click image to view fullscreen.


-Coolant bottle and aluminum bracket on which the PS reservoir will also be mounted
-Fuel filter
-Turbo intercooler and fan assembly
-ECU to dash wiring harness
-Misc clamps
-ECU to engine bay harness
-Fuel pump kit (center)

Another shot of the intercooler:
Image may have been reduced in size. Click image to view fullscreen.


My engine is being loaded on a freight truck by the end of the week, so should be here in a week and a half or so. I'll get these parts installed while I wait.
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PostPosted: Thu Feb 22, 2018 5:56 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Looks great Red Beard! You’re nudging me back in the FAS direction. I had a weak moment and looked at a Subaru conversion briefly.
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PostPosted: Thu Feb 22, 2018 6:50 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Im weak and fell for the suby conversion. And I love it. But that video of the 0-60 was pissa. Love the sound of that motor when he lets it rip.

Anything is better than a 30 year old engine no balls. Your headed in the right direction although I think there are many good choices to be made when it comes to a reliable powerful conversion.
It will rekindle your flame.

I had a 73 crush a cinder block once. It was quick and unexpected. Be careful. Just dont want ya to get crushed.
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PostPosted: Thu Feb 22, 2018 7:38 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

Well thought out kit! What turbo and manifold does this use? What are the rumored mpgs this set up will yield. Any idea who writes the fueling maps/tuning? Boost levels, low compression pistons, fuel pressure?

I have a turboed ABA, sort of the predisessor to this conversion if talking water cooled VW cars. Putting around in town, short trips...I'm getting 13-14 mpg and highway 18-21. The power and drivability is great.
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PostPosted: Thu Feb 22, 2018 7:52 pm    Post subject: Re: Heart transplant: 2.1 WBX to FAS Gen V 2.0T Reply with quote

i live in,,, califonia,,,,sigh
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