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Date:         Tue, 21 Jan 2014 15:47:29 -0800
Reply-To:     C B <cunegonde.van.westfalia@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         C B <cunegonde.van.westfalia@GMAIL.COM>
Subject:      1.9l WBX to 2.1l WBX Swap Tips?
Content-Type: text/plain; charset=ISO-8859-1

Since Cunegonde's 1.9l WBX is not too happy after an oil overfill, I have located a 1990 2.1l WBX replacement. It comes with the newer Bosch fuel injection set-up.

What do I need to know about the swap? What consumables will I need? Gaskets, bolts, hoses/clamps, wires/connectors, sealants, liquids (aside from fresh coolant)? Mechanical fit issues? Will the existing 4-speed manual transmission mate correctly, and is it appropriately geared? Remove/insert from above or below? (I'm working at home, no lift, but lots of ramps and multiple hydraulic jacks) Will I need the 2.1l exhaust headers, transverse pipes, c-pipe or muffler? Exhaust brackets different? Engine mounts/bed rail fitting issues? 1.9l starter re-use issues? 1.9l alternator re-use? 1.9l waterpump (I have a new spare)? Attaching and setting up the new FI system necessary? My original ECU has never caused Vanagon syndrome, but as we all know is neither fuel-efficient nor provides much HP. 1.9l airbox/filter OK? Other sensor or wiring harness details I should know? I have an aftermarket tach on the '83.5 speedo-clock-type dash instruments. Is is connected any differently on the 2.1l? Anything I've missed?

Oh, and this is temporary - a season or two while I source a modern VW inline-4 and save my pennies for a (custom?) transmission to match it. I'll tackle those questions in the next email.

-- Bretts

1983 1.9l WBX Ivory Westfalia "Cunegonde"


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