Date:         Tue, 15 Jun 2010 09:28:32 -0700
Reply-To:     Don Hanson <dhanson928@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Don Hanson <dhanson928@GMAIL.COM>
Subject:      VW Inline 4 motor 'revise and re-install' update, (long)
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I've been gathering parts  for about a week and a half now to swap out the
1.8L VW inline 4 block in my 84 5sp Van for a 2.0 liter block.  The 'new' 94
Jetta block (with it's supposedly better forged crankshaft and under piston
oil-squirter system) is now sitting ready to go on my new Harbor Freight
engine stand ($39..how they do that?)
  I'm not a mechanic.  I've been involved ($) with building some motors but
I've paid to have the important complex stuff done by 'real' guys.  This
motor  project is teaching me some of what I never had to actually
understand before, paying someone else to know.   The Vanagon/Inline 4 seems
a  perfect 'school-project' vehicle...inexpensive parts, easy to work on,
etc.
  My van's been running great.  I have always has a slight oil leak (rear
main seal?) and the P.O. who did the engine swap was sort of 'sloppy' with
the details...many of which I have 'cleaned-up' some as I go along.  I've
had this vehicle as my main ride for about 2yrs.  Recently I scored the
Jetta motor on my local Craig's List for $100 complete so rather than
replacing the seal on my 1.8liter, I am replacing lots of stuff..."while I
have the motor out"  Mainly using the 2.0 liter block with all the existing
1.8 liter parts.

   The inline 4 VW gas motors--they evolve.  They've been around in the same
basic form for years and there's lots of information on how to work em.
They're like the Small Block Chevy motor used to be...

  My Game Plan is to gather all the stuff and have things planned to
minimize Down-time for the van.  I'm now ready to go.
  I've found some good parts and information sources along the way.
  From Techtonics Tuning (Oregon) I found all the parts to swap on my
Digifant 1.8 liter head and engine management system.  Very helpful guys.
They sell a bushing kit to swap in my old distributor and another belt and
idler pulley to easily eliminate the power steering/AC serpentine belt from
the Jetta III block.
  German Auto Parts supplied me with the seals and gaskets..Quick delivery,
knowledgeable customer service.  Pleasant to deal with.
   I found this site for my "to be fabricated later" exhaust system.
http://www.spdexhaust.com/
The Jetta III head has a dual outlet exhaust manifold that is said to
deliver significantly better power than the single outlet Jetta II (or maybe
I currently have a diesel 1.6 N.A manifold....) exhaust that  I'll be
installing, temporarily with  my current head with the existing exhaust in
place and then fabricating up a Merge Collector around all the suspension
and engine mounts after I can see how it should fit.
  www.siliconeintakes.com is another very interesting site I came across
while looking for some parts to clean up the intake the PO devised.  I have
not bought from them but a quick search through the site...man, they got
lottsa stuff I could use...
  I should really have a Blog page for this kinda stuff...sorry list for the
length of this post..

  Don Hanson