Date: Sun, 12 May 2013 20:17:22 -0700
Reply-To: Jim Arnott <jrasite@EONI.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Jim Arnott <jrasite@EONI.COM>
Subject: ABA into 1.9 Vanagon was coolant overflow fears and thoughts
In-Reply-To: <002201ce4f70$c6f37ae0$54da70a0$@gmail.com>
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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
