Vanagon EuroVan
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Date:         Wed, 17 Mar 1999 11:53:37 -0800
Reply-To:     Mark R Drovdahl <mdrovdah@SPU.EDU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Mark R Drovdahl <mdrovdah@SPU.EDU>
Subject:      Engine Conversions (2.0L 4cyl) LONG was: Re: Vanagon w/Eurosport
              vw2.0 inline 4--->??
Comments: To: John Fowler <jfowler@ns.net>, Coddington <coddington@pacific.net>
Content-type: text/plain; charset="US-ASCII"

>From: "John Fowler" <jfowler@ns.net> >Date: Wed, Mar 17, 1999, 10:32 AM > > I'd like more info. > Thanks, > > John

I'll cc this to the list, just because.

Sure...I bought my '88 Westy in November w/140,000 miles. Knowing that the passenger side head was already oozing, I was banking that I'd get through till summer, when I'd have time/money/space to do my own repair. Murphy's law came around and sure enough late January and the van was overheating/gushing and barely usable. Money was/is kinda tight so I initially decided to have the heads done. I started by calling every German/VW/European care repair place in the Yellow Pages. I had estimates from $700-2200, with anticipated life-after head job between 30,000-120,000 miles. I also learned that since my engine already had so many miles, the next time it leaked it wouldn't likely be a canidate for repair moreover replacement. Well, I might repair my current boxer, but will never put another one in. Underpowered and flawed in design (see leaking heads), no thanks. So I got out the phone book and called everyone again, this time tossing out the engine swap idea. About this time the 5cyl conversion was getting a lot of press, but in CA not WA. Although I'd love to eventually try the 5, just so I could tow my boat, it's currently too much and too far away (Sorry Detlev). I found a local guy who's been doing Deisel to Gas conversions with rabbit motors (inline 4's) for quite some time (30+ jobs). I also talked extensively with David Marshall (list guru) about the kit his company (Fast Forward Autobahn Sport Tuning http://www.fastforward.ca) is going to produce for the inline 4. Only David, as oppossed to Europec, will sell you pieces w/out forcing you to buy the whole thing, engine included. To wrap things up here, I found a 2.0L 4cyl out of a '98 A3 Jetta w/only 6,000 miles. It was at a Volvo wrecker, had been stored indoors since it was yanked, was clean as a whistle, and they only wanted $1,000. I talked to my installer and picked it up two days later. Since then Jerry (the mechanic) has been collected the needed parts: engine mounts, cross members, diesel starter, bell housing, flywheel, clutch kit, and so on. Biggest hang-ups have been FI and exhaust. The A3 with its Motronic FI doesn't quite fit. Well, really none of the inline 4's fit perfect, all require a slight (4-6") modification at the front drivers side of the engine compartment. But the A3 w/Moto is too tall. So, we've traded the Moto head and FI to a local wrecker (Bry's) for a Digifant II head and FI. Jerry rebuilt the head and its just as pretty as the block. I did get considerably different views on FI's (CIS, Digi, Digi II Moto) however, after driving Jerry's (Digi II) van I liked what I saw. Plus it's what he knows best and is most efficient/comfortable with. The initial exhaust will be crap. It's off of a Diesel to Gas converted van, that was burned up...my project is too take Jerry's design, and improve/build my own. I've got some ideas, and it helps that my roommate has a pro-welding setup back at his folk's place. Apparently if you don't put some flex point in the exhaust system you'll forever be cracking pipes. Although Jerry's hooking me up on some parts for real cheap it looks like a typical budget can look something like this. - Motor ($500-$1000) - Conversion Parts (primarily Diesel stock parts) ($1000) - Professional Install ($1000) Some money can be saved in some areas, sometimes more money will be spent in others. If you're going to have someone else do it, shop around, find someone who preferrably owns a van (better if they own a 2.0L conversion van) and who's excited about doing the work. Well, hope that helps, if you want/need more specifics just holler. I'm sure a lot has been left out...Once again I'm no VW mechanical genius, I just read everything I can get my hands on (Bentley first) and don't shy away from asking "stupid" questions to people that know more than me. Thanks to all who've answered them.

Best of Luck, Mark Drovdahl '88 Westy (soon to be '88 A3 Westy) Seattle, WA 206.545.4492

----------

> >>Currently in process...I'm using a 2.0 L out of an A3 >>(1998) Jetta into my '88 Westy. I'm planning on a larger >>post to list when it's done - maybe a website, sometime >>in the next two weeks...until then, if you want specifics, >>beware I'm not a VW certified motor-head, Pmail me. >>Looks like total cost will be around $3000, my kit not >>Eurospec's. >


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