Date: Thu, 6 Apr 2000 08:36:22 -0700
Reply-To: Stuart MacMillan <stuart@COBALTGROUP.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Stuart MacMillan <stuart@COBALTGROUP.COM>
Organization: The Cobalt Group
Subject: Re: Westy Engine Swap questions 1.9L to a 2.1L
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I could write a book on this, I have been working on this swap for my
'84 now for a couple of weeks. Maybe I'll write it up if Ron wants to
post it on Vanagon.com, it is not to late to take some good photos!
First, it is an excellent idea, but some things need to be kept in
mind. You use the complete exhaust, water pump, and thermostat housing
from the 1.9. The exhaust and plumbing are radically different for the
2.1 version Vanagon, and it is not worth trying to convert a pre-2.1
Vanagon over to this design.
One surprise I encountered was that the intake plenum and throttle body
that came with the 2.1 are a larger diameter than on my 1.9, by nearly
1/4"! I have never seen a reference to this fact anywhere, so be sure
to get these parts with your engine. This also requires modifying the
vacuum line routing a bit.
Everything else is the same, ECU, injectors, etc.
You are then faced with a choice about the stock water cooled oil
cooler/filter set up for the 2.1, which will no longer fit with the 1.9
exhaust. One school, including Bob Donalds of Boston Engine, says just
leave it off, others say it is needed since the 2.1 runs hotter. My
engine came with an external setup that the PO had mounted in the left
rear wheel well. This is just standard VW remote oil filter adapter
using the long nipple (removed from the 2.1 oil filter/cooler mounting
location) and the short nipple from the 1.9 replacing it on the engine.
This also requires drilling and tapping the water pump and t-stat
housing for coolant line fittings for the oil cooler, another expense.
I suppose you could run it as an air cooled cooler if you wanted!
I will most likely place this setup inside the engine compartment,
probably next to the ECU in the corner. I have not sorted this out yet,
but it will probably be strapped in the corner to keep it from moving
around, but removable so the filter can be changed. Or, who knows, I
may decide to just take it off and go the Bob Donalds route!
Next Saturday is decision day!
Any others out there with experiences to share on this topic?
--
Stuart MacMillan
Manager, Case Program
800-909-8244 ext. 8208
Fax: 206-269-6360
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http://cobaltgroup.com
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