Date:         Tue, 1 May 2007 22:18:17 -0700
Reply-To:     Don Hanson <dhanson@GORGE.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Don Hanson <dhanson@GORGE.NET>
Subject:      Engine conversion..One altermative..
Content-Type: text/plain; charset="Windows-1252"

I bought my GL with its I-4 Cabriolet motor conversion already done, so I can't say for sure how hard it was, but looking around in there for almost a whole year now, it doesn't look like the fellow who did it  had to do very much fabricating or fiddling Lurking over on the  SubieVan list, it seems like that type conversion calls for lots of messing around, if you don't get a "full kit"..This is the second inline four he'd converted, using, I understand, a motor mount kit for a diesel motor, but installing a 1.8liter Cabriolet motor with hydro lifters and digifant injection..It looks like most of the parts are 'plug and play' from one motor to the other...
  All this new machinery fits very nicely under the standard deck cover., kinda canted over to the driver side.  The 2.0L inline four, that may be a different story because the intake is on the other side of the head and would probably have clearance issues with the deck lid.  I hear you can use a head from the 1.8 on the 2.0.  There is plenty of room to work on everything.  The motor is much lighter than the wbx motor, I am guessing here.  It is no power house at a Bentley-rated 94hp only and 100 ft/lbs of torque..but mine seems stronger than that without any California smog stuff mandated here yet in Washington state.   I have a mild camshaft swap that will go in tomorrow when I pull the head to replace the head gasket..said to be about half a day's work, motor in place...General knowledge says expect 10-12 more hp with the cam and no change in drivability.
   It is ironic that I wanted a conversion motor because of the WBX motor's widely acknowledged penchant for head problems.  My first major problem is...a blown head gasket..Caused, of course, by my unfamiliarity with the Vanagon's idiosyncrasies.  I replaced the coolant and neglected to purge all the air, causing overheating, which is a no no for the inline 4, I have come to learn...
  The 5 speed manual trans has a very low low gear.  I understand this is from a diesel van..Seems just right for the gas motor, and that crawler 1st gear is useful in the rough terrain.  
  So, with the little motor conversion you won't be blasting over the Grapevine at 85mph like some guy just mentioned doing in his 2.5l Subie...just before he blew a rod through the case...but it will hold 60mph in 4th on a 6% climb and do a comfortable 75 all day on the flats, getting about 23mpg at that speed, with gear aboard...
  You don't hear much about the I-4 except that Tiico (?).  So hopefully, the list is a bit more aware now of another possible choice for our vehicles driving force..Looks easy (when it is done) and simple to stick in a Golf, Cabriolet, new beetle, whatever motor and parts are real plentiful and cheap and interchangeable with many other VW models.
  Don Hanson