Date:         Mon, 13 May 2013 09:14:04 -0400
Reply-To:     Larry Alofs <lalofs@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Larry Alofs <lalofs@GMAIL.COM>
Subject:      Re: ABA into 1.9 Vanagon was coolant overflow fears and thoughts
Comments: To: Jim Arnott <jrasite@eoni.com>
In-Reply-To:  <10AD58D8-6C2C-48AB-9798-AD8EF43B923E@eoni.com>
Content-Type: text/plain; charset=ISO-8859-1

??
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
>