Date: Mon, 13 May 2013 09:59:04 -0700
Reply-To: Don Hanson <dhanson928@GMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Don Hanson <dhanson928@GMAIL.COM>
Subject: Re: ABA into 1.9 Vanagon was coolant overflow fears and thoughts
In-Reply-To: <88591FF84D0C4A4DA516079041BD7EAD@JimArnottPC>
Content-Type: text/plain; charset=windows-1252
Small boat rigging is good for that stuff...like maybe..
http://www.unicornstainless.com/WireRope.html
My throttle cable is from a bicycle brake cable...the end was just right to
go into my throttlebody linkage on the 1.8 head....
On Mon, May 13, 2013 at 8:29 AM, Jim Arnott <jrasite@eoni.com> wrote:
> Throttle cable. I spend 3 hours searching the Internet looking for
> throttle cable material before I stumbled on a Chevy engine swap site that
> mentioned Home Depot. 1/16” diameter, 9 strand twisted into one cable, itty
> bitty wire rope. Stranded wire comes in two configurations. 1x9 & 7x7 IIRC.
> 1x9 is what you want. Home Depot has it. $0.27/ft.
>
> Jim
>
> From: Larry Alofs
> Sent: Monday, May 13, 2013 6:14 AM
> To: Jim Arnott
> Cc: vanagon@gerry.vanagon.com
> Subject: Re: ABA into 1.9 Vanagon was coolant overflow fears and thoughts
>
> ??
> 20' of 1/16" 1x9 galvanized wire from Home Depot
> ??
>
>
> On Sun, May 12, 2013 at 11:17 PM, Jim Arnott <jrasite@eoni.com> wrote:
>
> On May 12, 2013, at 5:28 PM, Stuart MacMillan wrote:
>
>
> And you can add a turbo too! The folks at FAS have an elegant 2.0
> package,
> but it's way too expensive for me. Where is the documentation,
> parts, etc.
> for a junkyard DIY ABA engine conversion? I don't want to fabricate
> everything myself and figure out the wiring, plumbing, mounts,
> exhaust, etc.
>
>
> It ain't a kit. As the late Bob Hoover said, YOU are the mechanic in
> charge.
>
> Photos:
>
> Work in Progress: http://tinyurl.com/czp7tvl (Note: The orange bus in
> the first couple pics was the model. That is an ABA into an '82 diesel)
> Finished product: http://tinyurl.com/bvrra5g
>
> Parts:
>
> '96 92k mile ABA complete from a Trek Jetta that was junked due to
> immobilizer problems
> Engine wiring harness from same '96 Trek Jetta
> ECU
> alternator
> hoses and coolant reservoir
> timing belt & tensioner
> windage tray
> 6" of the exhaust header pipe from the donor
>
> '83 Diesel:
> carrier bars
> engine mounts
> motor mounts
> oil pan
> oil pickup
> oil filler
> dipstick & tube
> exhaust mounts
> bell housing
> bell housing dust shield
> bell housing to engine attachment bolts
> transmission input shaft seal
> either a diesel input shaft or shorten wasserboxer shaft 10 mm
> transmission to bell housing gasket
> flywheel
> clutch & pressure plate
> throwout bearing
> starter
> engine compartment cooling hoses
> thermostat housing
> steel engine cover
>
> '86+ 2.1 Vanagon:
> intake snorkel
>
> '98 VR6 Passat
> water pump pulley
> DLC & a piece of the harness (about 6" long)
>
> ''98 Ford Escort Zetec
> Air cleaner
>
> 16" 2 3/4" aluminum irrigation pipe
> Intake hose from some junkyard Audi that was the right shape.
> Miscellaneous cooling hoses from NAPA. (numbers to come)
>
> 20' of 1/16" 1x9 galvanized wire from Home Depot
> 20x1032 serpentine belt (no A/C, no PS.)
> 120amp Cole-Hersee continuous duty relay for the house batteries.
>
> Exhaust system:
> custom fabrication
> 34" 1.75 dia secondary pipes dumping into a 2.5" collector to a OBD II
> extra load universal cat to a 700 oval 3 pass muffler and 3 hours of
> labor.
>
> There are probably additional parts/pieces, but that'll get the engine
> in the hole. The most challenging part of the whole process was
> marrying the DigiJet Vanagon to the ABA's Motronic engine management
> system. You only need three wires: Power, switched power and ground.
> Getting those three wires hooked up to the the right places took an
> ASE master technician/mechanic. After he's recovered a bit, I'll get
> the documentation.
>
> The only downside to this conversion is now I have to haul 2 Bentleys
> around. Vanagon & Jetta. Small price to pay. It has transformed my
> Adventurewagen into a real car. And I picked up 3 mpg as well.
>
> Jim
>
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