Date:         Sun, 19 Sep 1999 23:53:36 -0700
Reply-To:     daveb@CP.NET
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dave Bayer <daveb@CP.NET>
Subject:      notes on SA 2.0L inline 4 conversion
Content-Type: text/plain; charset=us-ascii

So living in the SF Bay Area, and liking the sound of the
inline 4 engine conversion that Peter B was talking about,
I drove out to take a look at it. I've got a couple tech
questions for those who have access to Bosch manuals
so if you don't want to read this but would like to help
with those, skip to the astericks...

This conversion is based on a 2.0 "nontall" block (the block
actually had a 1.8 cast mark on it, but Peter's guide
said it was a 2.0L engine). To look at, the conversion
is very clean. Since the SA kit does not use the tall
block, there is no interference from the frame rail -
though it is a close fit. The van felt more powerful
than my syncro's wasserboxer. Noteably, I had trouble
getting his van into 1st, so I just started out in
2nd from starts; the engine didn't seem to have a problem
with this. Also, there is no cutting of the input shaft
on the tranny. There is a little clipping of sheetmetal
in the engine compartment - which I believe was documented
in his webpage. The van held and accelerated on reasonably
steep hills (not like my motorcycle but that's kind of an
unfair comparision). The increase in power probably isn't
going to blow your socks off, but did allow meto maintain
60 in 4th on the hills just east of Folsom Lake on US50
for those of you who know the area (just east of Sacromento).
This was with an empty van, so next time I'll bring
a few bags of sand to simulate the load I usually am carrying ;)

When I drove it, it had 60 miles on the second tank of gas
since he put the motor in the van, so I have no idea as to
what kind of mileage this thing gets.... Also, Peter said
there is a separate kit for the syncro, the information for
which he is waiting on. There are some possible problems
with supporting the skid plate as the I4 extends to and just
past the point where the old engine carrier crossed the rear
of the van. So I guess some of this maybe premature until
he gets his hands on these documents...

Ok, so on to the pros and cons:
pros:
- It's more powerful, but it is hard to say how much more
        just from driving it.
- It's clean and easy to get at everything. I think it's
        easier to get at most of the stuff than in my golf.
        There is a little more clearance than in my golf
        to access the timing belt cover, etc.
- In terms of conversions, the intake on this one is very nice.
        Nice rubber boot coming off the throttle body (and air
        meter?) going to the air cleaner which retains the
        snorkel (albeit on the other side of the van).
- No cutting of the input shaft.
- Nice exhaust system (in terms of grade of tubing,
        radius of curves, etc).

cons:
- Increased noise on full throttle acceleration. This seems
        to "plague" all I4 conversions. Would like to have
        had a long time to play
- removal of stock power steering reservoir mount in the engine
        compartment. I have forgotten why you need to remove
        this - I think it will interfere with the alternator.
        This just means you would have to do some welding if
        you ever sold your van and wanted to put your conversion
        into the other van you had/were buying ;)
- Possible smog issues at least in CA. The SA vans do not have
        an O2 sensor, so the wiring harness for this conversion
        does not include a port for the O2 sensor. More below.
- Since this is a SA engine conversion, there is a possiblity
        that I will not be able to get replacement parts for
        it (like the custom heater pipe extensions that
        replace that plastic coolant manifold on at least
        86 and up vans)...

Ok, so my only real problem is with the possiblity of not
having an O2 sensor as without an O2 sensor, there is no
way I can convince a CARB referee that this engine could
be anything like an engine out of a later VW.

***************************

So what I now and trying to figure out is if the Motronic ECU
has a pin out for an O2 sensor. So far, I have not been able
to find any techincal data on any of the Bosch ECUs except
those that were used in the vanagons ;) If someone could
tell me if Bosch part 9 261 204 017 (978) has an O2
sensor pin in it, it would be GREATLY appreciated. Or if
anyone knows of a source of information where I can start
tracking this down, I would greatly appreciate it... I really
would like to get one of these into my syncro before the
snow starts falling in the Sierras ;)

TIA

dave