Date: Mon, 18 May 2009 16:42:02 -0700
Reply-To: Don Hanson <dhanson928@GMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Don Hanson <dhanson928@GMAIL.COM>
Subject: Re: inline 4 swap
In-Reply-To: <c4e7c5f90905181517yc96990chbd4aa5b99d9fa8fa@mail.gmail.com>
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Mark, with the motor you chose it should be almost a bolt-in. From what I
was told by the guy who did mine, the 1.8inline block is a carbon copy of
the diesel. He was a millwright/door builder (not a mechanic) and he says
he's done a couple of these. He says he did the one I have in one day, with
the help of one guy and the use of a hoist. Then he drove it, trouble-free,
to California and back to Washington state, leaving the next
morning. Living with my inline transplant now for a few years, I have no
reason to doubt this guy's story of a one day swap-next day 2000+ mile trip.
The only real fabricating done on mine is a small clearancing on the
inside left 'fender liner'.. for the front (direction of van travel) of the
intake to fit in the engine bay and an intake 'duct' that goes across the
front of the engine bay from the Vanagon AC to the intake along the drivers
side of the inline motor..My guy used 4" alloy sprinkler pipe and welded it
into shape..You could probably use PVC also...
You will also have to do an exit for the exhaust...mine kinda follows the
vanagon route behind the motor but in front of the bumper and out the right
side.
Do 're-install the cross engine brace that comes with the diesel. The
right side (up side) motor mount takes a lot of twisting load with the motor
tilted. I understand that some of the guys leave these off like mine was
and I broke the bolts off on my motor mount before I discovered that there
was supposed to be a brace there. I made one up of u-channel steel that
works just fine, after just barely getting the broken bolts out of my block
and replacing the motor mount that broke..
Autotech (google it) sells a mild camshaft for about $125...worth doing if
you want to bother. You can do it in a couple of hours after your motor is
in, too. Adds about 15hp to my motor..
Don Hanson
On Mon, May 18, 2009 at 3:17 PM, neil N <musomuso@gmail.com> wrote:
> On Mon, May 18, 2009 at 1:25 PM, pdooley <psdooley@verizon.net> wrote:
> > Some input shafts will bind in these conversions. Not sure if it's the
> > diesel input shaft or the WBX.
> > The shaft is a little long and will bottom in the I4 crank snout, binding
> > the motor and putting huge stress on the trans bearings and engine thrust
> > bearings.
> >
> > The input shaft can be clearanced with an angle grinder, just lop off a
> > quarter inch or so.
> > Of course, do a dry run on your setup to see if clearancing is even
> > necessary.
> >
>
>
> The diesel shaft should be the correct length as is. No need to cut.
>
> Though I used a KEP adaptor plate, I had to cut the input shaft on my
> air cooled tranny. I'm *just* about certain the WBX shaft also needs
> to be cut.
>
> To give a rough idea, cut, input shaft on my swap sticks out just over
> 1/2" from clutch housing face:
>
>
> http://tubaneil.googlepages.com/InputShaftCut.jpg/InputShaftCut-full;init:.jpg
>
> A set of calipers should aid in determining length. Shaft should be
> long enough to ride properly in pilot bearing, but not so long that it
> butts up against hole in flywheel. Hole in FW may be tapered near end.
>
> I used a Dremel with proper metal cut off wheel. Took my time, kept
> wet rag on shaft.
>
> Consider installing a windage tray.
>
> It's possible your '91 engine won't have a pilot bearing. On my ABA
> swap, I installed a 15mm long PB. IIRC, it was for a Fox engine and
> AFAIK, is a sealed type. It sits flush with face of KEP "Vanagon"
> flywheel. Pic shows Vanagon bearing on RH and one I installed on LH.
> No issues so far. (knocks wood ;) I can provide a couple of PN's.
> Bills don't show which is which.
>
> http://tubaneil.googlepages.com/abaswappilotbearing
>
> Check for excessive play between clutch cross shaft and bushings.
>
> Neil.
>
> --
> Neil Nicholson '81 VanaJetta 2.0 "Jaco"
>
> http://tubaneil.googlepages.com/
>
>
> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines
>
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