Little Blue Truck gets a new engine - FAS 2.0 engine conversion

[VicVan]

Ok, don't need it. I guess I can remove it then?

Just curious, what's it for? The cruise control already receives an electric signal if the brakes are depressed.
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[Zeitgeist 13]

It's a redundant system; using both vacuum and electrical signals. This cruise system is really nice when it works, so unless you're morally opposed to the concept, I'd just leave it dangling, or at least pull it as a complete kit to sell to the next guy.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[VicVan]

It worked very well on the WBX. Unfortunately, it is not compatible with the new engine. I'll take it out and put it in the parts bin, with the other cruise control components. Thanks for the info.
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[VicVan]

Finished fixing the bumper,
treated some small rust spots on the body behind the bumper,
cleaned the inside of the frame rails (bumper to rear crossmember @ firewall - will spray Fluid Film in there),
installed dash harness,
started installing the cruise control unit,
new throttle cable,
installed ECU harness and ECU bracket.

It seems like the number of steps backwards for every step forward is decreasing. That's a good thing.

Notch the wall of the water tank enclosure slightly, because that harness connector is huge:

Trim off some of that bench sidewall too, so the harness isn't too tight, a few screws, and voila!

Dang, they put the sticker upside down...
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[Vana Guy]

Was wondering if there is any metal on the bottom of the ECU.

[VicVan]

What do you mean? The ECU is enclosed in the aluminum casing you see. The only place non-metal in that casing is the part on the top, with the electrical connectors.
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[VicVan]

Man, adjusting the engine carrier bar mounts was a lot more work than I thought. Bumper brakcets had to be threaded, holes had to be enlarged, metal to be straightened, metal had to be ground down... But it's done! I can finally install the carrier bar on the engine.

Supporting the carrier bar for dry-fitting

Reinforcement blocks in place, holes enlarged, rust treated:

Dash (almost) complete:

Harness through front wall (I reused and enlarged the existing hole for stock cruise control vaccum tubing):

Drive-By-Wire accelerator pedal, here seen at the oddest possible location, because the Vanagon's automatic transmission was designed in 1370 and does not know what an electron is:

Tomorrow: finish dash install, coolant bottle bracket, bits and pieces (firewall fuel spigot, electrical connections, coolant lines, MAF-airbox adapter, air filter, fuel filter), and, oh, mating engine to transmission, ATF dipstick modification...
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[VicVan]

Another good day today, many small things completed.

Finished installing the dash

Coolant and Power Steering tanks bracket

Fuel spigot (I got rid of the original plastic one a long time ago, and was replaced by hose, but since this part is included in the kit, might as well use it!)

ECU installed. I need to make a metal or wooden enclosure to protect the ECU and harness

Engine bay ready for install... Notice the stainless steel coolant tubing on the right

The AVH spreading its tentacles over the good'ol tranny:

Tomorrow: ATF dipstick modification, engine to transmission mating, and if all goes well (sure it will...), raising the engine in the bay!
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[VicVan]

I need to modify the ATF dipstick, because it now interferes with the engine. I have to bend it towards the passenger side. FAS recommends using a small propane torch, and bending it a in few steps. Any tips before I tackle this?
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[VicVan]

Dipstick modification:

Engine and transmission were mated together, and put on a rolling cart

Engine is then lifted in the engine compartment:

Aaaand... engine is in! And no, I don't have pictures, forgot to take some with all the exictement...

Thanks to Wayne for coming over and helping today! Thanks to my Dad and my buddy Max too.
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[Vana Guy]

[VicVan]

Thanks!

That's good to know. Yes, this ECU is a metal box on all sides. The bracket is aluminium too, but too small to be a heat sink (and it's aluminium, not great for heat conduction). The ECu is mounted as per FAS' instructions, but I'll keep an eye on the temperature of the box, especially in the summer. Thanks for the tip.
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[khughes]

[VicVan]

A little teasing in the meantime... Seen from below.

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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[VicVan]

Crankshaft rotating tool, reference M12-2x4

FAS bracket and cable, going from the transmission kick-down lever to the Drive-By-Wire pedal

Remember that boot for the end of the shifter cable that's NLA? I found a quick and cheap fix. Not ideal, but not bad:

And when you think you've seen it all, and all the bad stuff is behind you, and all you have to do is install new parts... You shear a transmission mount bolt, because your torque wrench is a piece of crap (remember, always blame your tools). And then as you're removing the piece of screw in there, you break the nut free (the one that's welded from inside the frame rail). Fun.

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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[4Gears4Tires]

Man, that's a lot of progress and then a serious setback. We've all been there for sure.

What is your fix for the broken captive nut? A rivnut could work. But if the spacing is off, you might have to weld it shut, drill through the weld (fun), and then install the rivnut.
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition

[VicVan]

There's a hole in the framerail nearby. I can almost access the top of that hole. I'll try to JB Weld the original nut back in place. If it fails, Rivnut, thanks for the idea. Never done one of these, but I guess it's time. I just don't want to remove all the engine mounts, put the cherry picker back on, etc. so I can lower the transmssion and get clearance to install the rivnut.
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[VicVan]

Connecting vacuum hose from brake booster to engine. Inner diameters are fairly similar. Do I just heat up the black tube with a heat gun, or do I need some kind of adapter? (Picture should be rotated 90 deg clockwise...)

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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[skills@eurocarsplus]

get some of this:

https://www.busdepot.com/n203741

it should slide over both pieces without a problem
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[VicVan]