Date: Mon, 8 Jan 2001 21:27:35 -0800
Reply-To: Michael Snow <mwsnow@HOME.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Michael Snow <mwsnow@HOME.COM>
Subject: Diesel 4 speed vs. 5 speed (was RE: "windage tray" and other I4
conversion comments) LONG!!!
In-Reply-To: <01C079C8.6101C560.southard@gis.net>
Content-Type: text/plain; charset="iso-8859-1"
As you noticed, Bentley says nothing about any differences between the 4 and
5 speed diesel Vanagons. However, the ETKA CD has some crude illustrations
that show the parts and numbers. The basic differences are mostly related
to the 5 speed transmission being about 10cm longer than the 4 speed. To
accommodate the difference in transmission length, the following parts are
different from the 4 speed. Some are standard waterboxer parts:
The engine carrier bars are curved differently and mount to the body using a
different bracket system. The rubber motor mounts are moved to the new
location and redesigned to eliminate the flat steel crossbar that goes from
side to side on the 1982 vans.
The long coolant pipe (running to the front of the van) that is closest to
the center of the van is changed to the newer style, like on waterboxer
vans, and terminates in a different location in the engine compartment. The
coolant expansion tank is redesigned and includes a provision for a coolant
level sensor (like waterboxer). The new expansion tank has different sized
hose barbs than the old one. You can guess what comes next...
The combination of the expansion tank and the coolant pipe necessitates a
different hose design. Of course it is the huge octopus that runs from the
side of the cylinder head and is the most expensive hose in the engine
compartment. I speculate that the hose between the head and the heater is
longer, but there may be enough slack in the 1982 hose to make up the
difference. The coolant overflow tank (behind the license plate door) is
changed to the waterboxer style for engine clearance.
The reduced space between the engine and rear of the body necessitates a
different oil filler tube, which is curved at the bottom to clear the
muffler. It is made of steel instead of plastic and has an unvented plastic
cap. The cast aluminum elbow between the dipstick tube and the oil pan is
eliminated, as is the troublesome o-ring.
Because of the curve, the oil filler tube cannot accommodate the dipstick,
which is moved to the center of the block in the same hole that the cars
use. The dipstick tube rises straight up from the block, makes a gentle 90
degree bend and continues horizontally to the rear of the van. It bolts to
the injector pump bracket for stability. Mine cracked from engine vibration
at the mount point and needs to be replaced :-( The dipstick handle is
still available through the license plate door, but my hands get much
dirtier checking the oil than they do on the '82.
The oil pan itself is interchangeable with the 1982 model, but incorporates
an updated drain plug design and a threaded hole on the side of the pan for
the turbocharger oil return line on TD vans.
The air intake system uses a different rubber elbow between the filter box
lid and the magic cyclonic elbow.
The entire gear shifter system, from the knob all the way to the
transmission is different.
Even with all of this stuff, I have probably still forgotten something! I
contemplated swapping a 5 speed into my 1982 Westfalia for some time before
the opportunity to buy this 1983 model came along. I'm glad I didn't try to
tackle the job without a factory installation to use as an example. Not
that 5 speed transmissions were falling from the sky anywhere near my
house....
I hope this helps somebody. It's past my bedtime, I'm tired, and I have to
prepare to pick up ANOTHER diesel VW tomorrow to add to my ever growing
stable of never-ending projects. $100 for a Golf 4dr 5spd with blown
engine! I just can't say no :-)
Mike Snow
<snip>
Mike, what is it about the 5 speed transmission that precludes the use of
the 1982 style dipstick system? I don't follow this. Also, what is the
advantage to the steel oil filler tube versus the plastic one on my '82?
Is it steel or aluminum (as is the oil pan and the L-shaped flange that
mates the filler tube to the pan)? Bentley doesn't seem to mention
anything different about the 83 5 speed set-up.
<snip>
