Swaps
From VanagonWiki
Who wants to tackle this subject? It can't be a promotion for any particular upgrade, it should be informational.
Contents |
[edit] Time for different engine? Information to consider
Some Vanagon owners are satisfied with the performance of their stock engines. Some desire, or truly need, increased power, reliability, and efficiency. Each individual has different needs and circumstances. Determining these, choosing an engine manufacturer, getting all the parts, or finding a shop to perform the install, can be challenging.
The swap can be done by the owner if the owner has good mechanical skills, a proper set of metric hand tools and access to engine removal/installation tools. If not, there are shops offering installed "turn-key" packages, or "turn-key" packages, conversion kits, and parts for the owner or mechanic to install.
Properly maintained and sensibly driven, most engines will provide a certain degree of reliability. Proper installation, maintenance, condition of the "used" engine, which model of Vanagon it is installed in, the skill level of the installer, the type of driving it will be subjected to, are some of the factors contributing to the reliability and efficiency of the engine.
- Locally available donor vehicles.
If the conversion is done by the Vanagon owner, having a locally available donor vehicle is beneficial. Importing and/or transporting a vehicle over any great distance may increase project costs. In different regions, there may be an abundance or deficit of a given vehicle which could influence the owners' choice in the engine used in conversion.
- Donor vehicle, or used engine?
Purchasing any used engine, presents varying degrees of risk. Shops offering conversion parts and/or services, may offer tested used engines. In this case, the engine will likley be higher in price, but an unknown used engine, failing prematurely, could end up costing more. Considering the time and money invested in a conversion project, taking the time to purchase a known working used engine, is crucial.
- Environmental concerns regarding fuel types.
Some Vanagon owners may feel that converting to a different engine, will help reduce emissions. Some turn-key conversions are setup ready for Ethanol blends providing an alternative to straight gasoline. Diesel engines provide the oppourtunity to use anything from straight diesel, to SVO. (Straight Vegetable Oil) These fuel alternatives may be obtained more easily in certain areas than others.
- Parts availability.
Having access to engine parts "off the shelf" is beneficial. Parts for engines typically used in Vanagon engine conversions, (parts not related to the actual conversion) are usually available. This may depend on the part needed and the geographical area the owners Vanagon is located.
- Engine technologies relating to parts availability
As a given engine technology ages, it is possible that parts will become increasingly harder to get, though this usually happens over a long period of time. One may consider this when choosing an engine.
- Who will repair my converted van?
For a variety of reasons, an independant mechanic may not work on a Vanagon with a non-stock engine installed. This could depend on which parts were actually used, who performed the installation and the quality of the install. If installation performed by a well known shop specializing in engine conversions, the independant mechanic may perform the required work. Hopefully though, if owner-installed, the owner will have a good chance of trouble shooting and repairing the problem themselves. If conversion done by a shop, the shop will likley be able to help maintain the vehicle.
- Cost aspects of conversion.
Conversion costs depend, in part, on the technical demands of the conversion, how the parts are procured, which model Vanagon they are installed in, and all related labour costs.
Project costs can be lower when piecing together "used" conversion parts. A conversion kit, containing most or all of the needed parts, will cost more. This increase may be a worthwhile expense, especially when taking into account the time required in putting togeter ones own parts. "Turn key" conversions (engine and its' related components assembled) will cost more, due to design and manufacturing costs, testing, inspecting and reconditioning of the engine and assembly of the parts.
Installation labour costs range from zero (DIY), to the cost of a shop doing the actual installation. If a DIY installation, having a running donor vehicle will likely keep costs lower. Donor vehicles may provide an engine that can be tested properly and with any luck, receipts of previous work done. These will help indicate the general condition of drive-train. If all parts are present, time and money will be saved in finding and purchasing parts that may have been overlooked. An added bonus; selling parts from the donor vehicle to offset the intial cost.
If conversion done by a shop, the installer will likely suggest a solution he feels is best. The customer should educate themselves regarding the installation procedure, inherent costs, and time required.
- Cost of operation.
Generally speaking, a diesel engine uses fuel more efficiently. Initial costs of a diesel engine and related parts may be higher than their gas engine counterparts. Use of diesel fuel may reduce costs over the long term, but driving habits and local pricing of fuel, may negatively affect this potential advantage. Engine maintenance costs will vary depending on the actual mileage of a given engine and the design ofthe engine.
[edit] Reasons to upgrade the engine
[edit] Reasons not to upgrade the engine
[edit] Available engine upgrades
(For each upgrade, list pros and cons, cost, turnkey information, ease of DIY, emissions issues, popularity, etc.)
(this section still in its infancy)
- Tiico: popular conversion based on a VW inline engine. Older kits were accused of vibrations and "buzziness". Recently redeveloped kit may have improved this problem. Good fuel economy reported.
-Zetec[1]: Praised for unsurpassed engineering quality, simplicity and ease of install. Unmatched parts availability and affordable long-term maintenance. The Zetec 2.0L DOHC is a 130hp engine that can be easily upgraded to over 200HP with bolt on turbo or supercharger kits. DIY kit (Bostig Core) install typically takes about 20 hours and can be accomplished by the novice mechanic with no special tools or skills required. Typical DIY cost is about $5K including low mileage (<10K) engine. Turnkey install with 10YR/100K mile warranty also available (Boston, MA).
Cutting edge engine management system features Fail-Safe Cooling, Passive Anti-Theft Security System & Failure Mode Effects Management. The Zetec is also the only currently available conversion for the Vanagon offering E85 compatability, a functional check engine light as well as Custom Engine Management Update Capability via the OBDII port.
-Subaru: several engine options available, most popular are 2.2l (135hp) and 2.5l (165hp) four-cylinder boxer and 3.3l (230hp) six-cylinder boxer. This is an open-source project with a large community with its own email group (subaruvanagon yahoo group). Many parts vendors, kit vendors and installers available in different parts of the country. Typical DIY cost is around $3k, but can be as low as $2k. Typical professionally installed cost is $7-8k. Fuel economy is about 10% better then stock (four cylinder engines). Conversion is praised for very smooth power, and a stock appearance as the subaru engine is about the same size and layout then stock. Drawbacks are complex electronics. Notable internet resources include:
Homepage of the yahoo group. Heart and Soul of the conversion
Brent Weides personal page with tons of info
Kennedy Engineering, the original inventor and major parts supplier for the conversion
http://www.subaruvanagon.com Started out as a how-to website, now the owners developed and sell conversion parts
[2]www.smallcar.com Major conversion parts supplier and installer
http://www.vanaru.com Conversiton parts and turn-key kits
http://www.mastercraftmotors.com Conversion parts and install service
-VW Diesel: several engines options available, most popular are 1.9TD and 1.9TDI. The most popular conversion in Germany, less common in the U.S. Costs are generally several thousand higher then gas engine conversions.
-VW Gas: inline-four engines out of the vw rabbit have proven popular especially due to the very low conversion costs, especially if the Vanagon is a diesel.
[edit] Notes on engine mounts
This section is an overview of the stock I4 diesel engine mounting system and custom made mounts for the various other engine swaps (ie Subaru, Tdi, I4 gasoline).
First off, the engine mounting arrangement in the stock Vanagon diesel (82-83.5, mounts differ slightly on later diesel and turbo diesel)
Following is a picture of the rear of the right hand carrier bar on an 1982 diesel. Note the rubber bushing that was done away with in post-1983.5 vans in favour of a "hard mount".
The following pictures shows the lefthand carrier bar of an 1982 diesel vanagon with its cast aluminum support in place. The supports bolt to the left and right side of the engine (4 bolt holes visible). The connection between the supports and the carrier bars is made through a rubber mount (rough sketch of mount below). The other projection from the cast aluminum support is for the muffler support bracket.
The astute observer will have noted, on the top diagram, a bar that runs transversely between the two engine carriers. It is thought that the bar is to prevent outward movement/oscillation of the longitudinal carrier bars. This bar was eliminated post 1983.5 when the modified carriers were introduced. Shown below is a rough sketch of the 1982-1983.5 engine mount (it connects the engine supports to the carrier bars).
note 1: for a discussion and pictures describing modifying the stock mounts see here.
note 2: for a discussion of TiiCo mount problems and solutions see here.
