Date:         Sun, 20 Oct 2002 22:54:31 -0600
Reply-To:     Simon Reinhardt <simon@FARRSIDE.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Simon Reinhardt <simon@FARRSIDE.NET>
Subject:      Update on my engine swap (very long)
Content-Type: text/plain; charset=US-ASCII; format=flowed

Hi Volks,
Some may recall my engine swap that started a few weeks ago... An Audi
2L into a syncro.
Here's where it is right now:
The adapter kit from Kennedy via Fast Forward arrived, and it was
immediately installed on the engine, which had already received new
gaskets and whatever diesel parts could be attached while it was still
out of the van. Then the no-fun-at-all process of getting the thing to
mate up to the tranny began.
The tranny had already received a new main shaft seal and bell housing
gasket.
Making the left-heavy engine slide into place was very difficult. At
one point the whole thing had to be backed out and dangled from a jack
handle across the hatch so I could grind a little bevel onto the tip of
the already-shortened main shaft (forgot!)
There were also some very helpful suggestions from the list at this
point. I think it was a combination of following those suggestions, and
being willing to hurt myself that eventually got the thing to slide in.
Next problem: my early-style diesel engine carriers had the rubber
mounts in the wrong spot! Actually, I think this probably had more to
do with the bell housing and adapter plate putting the engine in just
about the wrong spot, but whatever the factors, the mounts had to be
about 1-1/2" farther back on the carriers. This was accomplished by a
friend of a friend, who used a combination of angle grinders and scary,
dentist-like burr bits to get rid of the original welds. The mount
brackets had to be bent a very little to accommodate the rear curve of
the carriers, but they came out very nicely. The new welds are
top-notch; they look factory.
The carriers were then installed with a 1/4" spacer at the front, to
drop the engine to the correct angle. Thanks to those who got me the
measurements I needed at that point!
Finally, the van was on the ground. I'd already adapted the cooling
system while waiting for the carriers- I used aluminum tubing to mate
the radiator hoses to the diesel hoses, and replaced all of the heater
hose. A couple of minor hose-to-hose adaptations were made with a short
piece of galvanized pipe. The small hose that goes to the upper
connection on the expansion tank was too large- but the short hose that
goes from the heater pipe to the water pump on a Rabbit was a perfect
adaptor! I used the original 2.1 expansion tank instead of the diesel
one, purely because I could figure out how to mount the former.
The wiring harness was probably the easiest part. I got a complete
engine-area harness from an '88 GTI, since I'm switching to CIS-E.
After stripping out A/C, lights, and radiator circuits, I used a wiring
diagram and a VOM to ensure each wire's continuity (and presence!) Then
I taped each connector pair together and draped the whole mess over the
engine bay to put each connection in the general ballpark of it's
sensor or whatnot. Then, major taping ensued, after I labeled each
connector. The wiring harness was run in the same place as it's
predecessor, and all 3 computers live in the correct spot under the
rear bench.
Adapting the new harness to what was left of the old one was easy- the
only real work involved here has been making a new circuit for the fuel
pump, and the rest was pretty much just plug-in.
Since I'm putting the air/fuel meter in front of the left tail light, I
had to cut down the bottom half of it's housing. In the interest of it
being water-tight, it's now a congealing mess of plastic and blue
silicon, incorporating parts of a Fox airbox, a Scirocco 16V airbox,
and a section of the plastic tool tray that used to be attached under
my roll-around stool. Its intake will be connected to the original
snorkel with the tornado filter inline.
The last major fabrication area is the tube from the air/fuel meter to
the throttle: this will be tomorrow's achievement in white PVC.
My only real headache at this point is the lack of fuel fittings that
will attach to a CIS fuel distributor- banjo fittings from hell!



You're still reading this far down?!?

-Simon