Date:         Mon, 26 Feb 2001 09:58:12 -0800
Reply-To:     Dana Morphew <kadm@PUGETSOUND.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dana Morphew <kadm@PUGETSOUND.NET>
Organization: Dana's Mobile Carpet Steam
Subject:      Re: Trouble Fitting I-4 Engine Into '90 Vanagon
Content-Type: text/plain; charset=us-ascii

Mark, Robert, and Tom, thanks for your help.

To be able to use the '82 oil filler tube/dipstick combo, to avoid
rewelding the engine carrier brackets on the tubes, and to use the ACW
trans, I've decided to take advice and replace the stock ACW trans mount
with a mount from a diesel Vanagon.  Are there other mounts can I use to
accomplish this?

The forward part of the ACW trans mount welded to the horizontal plate
that bolts to the frame cross member appears to be offset a small amount
to the right of the trans centerline.  I don't know how much/if the
diesel mount is offset, but it will determine some of what needs to be
done to the rear shift rod to regain shifting after the change.  The
rear shift rod makes a dogleg bend to the right, as it leads rearward
and straightens for about a 25 mm. offset.  This bend can be
straightened and the clamp forward of the universal joint can slide 30
mm. further up the front shift rod to help regain shifting.  If the 30
mm. isn't enough, then cutting out a 25 mm. section from the rear shift
rod ought to do it?

When the ACW trans mount is attached to the 4 driver side holes, the
engine/trans centerline is noticeably skewed to the left.  Why are the 4
driver side holes used for diesel/I-4 installations?  My brother's '83
diesel 5 spd. trans mount is also mounted in the 4 driver's side holes.

Please give me input if you see something I've missed, and if anyone has
put an I-4 engine into a wasserboxer Vanagon, using the diesel mounting
parts, I'd appreciate hearing and learning from them.

-Dana-

Mark wrote:

there are 2 different sets of carrier bars, depending on the model
of tranny. You are using 1982 bars with a 1983+ type tranny. The 83+
bars locate the engine 1.5" farther to the rear. The simple answer may
be to modify the bars by cutting the mounts off and welding them back on
in the correct position.

There are other problems you may have in this conversion. If you are
using the 82 diesel oil filler tube it will hit when the engine is
mounted in the 83+ position.

You can use an air cooled tranny with the 82 engine bars if you get it
with nose mount and the rear half of the shift rod. The linkage at the
tranny is completely different from the ACW and other water boxer
trannys.

Robert wrote:

I know that the acw shift lever on the side of the trans is about 6
inches
farther back. When you change to the Diesel front mount, bolt it to the
set
of holes on the drivers side, you will then see your clearance problem
solved. But, now you have a problem with your shift rod going back to
the
trans, because the angle has changed and the rod needs a bend in it like
the
diesel one has.
The transmission and the engine both need all the Diesel hardware to
make it
work.
The trans needs the front mount, slave cylinder bracket, of course
bellhousing and pilot shaft, and shift rod or modified shift rod.
When I did my first conversion I didn't notice the 6 holes on the
crossmember
where the trans mounts bolts to. Leave this loose, mount all your bars
and
mounts, then bolt down the trans front mount.

Tom wrote:

I had very similar problems when I installed the I-4 using the aircooled
tranny. You can see how I solved it at:

http://volksweb.relitech.com/vanagon2.htm

I basically shortened the aircooled mount with a sawzall, and drilled 3
new
holes to make it sit lower.