Date:         Mon, 13 Apr 2009 07:49:36 -0700
Reply-To:     Don Hanson <dhanson928@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Don Hanson <dhanson928@GMAIL.COM>
Subject:      Engine alternative (inline four) a bit long
Content-Type: text/plain; charset=ISO-8859-1

  My 84 low-top camper has a '92   1.8liter 8 valve in-line four gasoline VW
motor and a 5sp tranny.  The conversion was done by the previous owner,
using the standard VW diesel Vanagon  parts to install the Cabriolet gasser
motor. It bolts right in under the deck at 50 degree slant, just like the
diesel did. (with some pretty minor cutting and welding of a frame member
for intake clearance)  I've been driving the crap out of it for a few years
now, putting perhaps 25k hard-traveling miles on it, with no complaints at
all.  I did do the normal Vanagon 'new to me' stuff when I first got the
van...Gas lines, filters, pumps, brakes, new rad. new alternator, etc etc.
I also have installed a new camshaft (260 degree) from Autotech (below) and
a performance Magnaflow SS muffler.  It probably performs like a very strong
WBX motor would, but it makes it's power  at a higher rpm range and gets a
little better gas mileage.  I find the 5sp tranny to be especially useful.
   I've also found working on the in-line four VW motors to be surprisingly
easy and relatively inexpensive.  For example,  replacing a head gasket
 (after I screwed up the cooling system bleed during my radiator
replacement)  and swapping in a performance camshaft ($150) took me just one
afternoon, about 3-4hrs.
   I've begun planning for when my present motor gets "tired".  When I do
re-power this van, I'm considering adding a little more power so I can haul
more stuff without becoming a traffic hazard.  I am about to get a second
1.8liter motor (they are readily available and plentiful for $300-$600) and
do a complete re-build so I can have a virtually new, more effective, motor
waiting-ready to plug in, when I want to.   (plus: I just like messing with
motors)   Below is the link to where I'm looking to source the engine
internals.  I was impressed when I installed their camshaft and they have a
good 'rep' with all the VW Sport tuning crowd.
  I am shooting for about 150-160hp using the lower compression
2-liter kit. That should be enough do get me down the road, smartly,  with a
ton of tools and toys in my van. Seems like that is close to what they get
from many of the (2.2) Subaru motor conversion vans.   I'll likely end up
with about $2500 invested.  I'll end up with a totally rebuilt motor, with
mostly new internals.  It'll still be easy to service and find parts or find
a mechanic/shop willing/able to work on it.  Whadya think?

http://autotech.com/prod_engine_engkit.htm

  Don Hanson