(translated
by
Joel B. Cort
from the vanagon mailling list, thank you!)
Rebuilding or Converting a Vanagon engine: The options available and what we can install for you...
VW 1.9 and 2.1 2.2 and 2.5
Note: prices (in Canadian dollars) and certain data (speed, displacement..) are approximate
------------BJP - Engine and VW parts and installation----------
VW 1.9L (1900cc) 1983 to 1985
Horizontally opposed, water cooled, 4 cylinder engine with hydraulic lifters. Pushrod actuated valves with gear driven camshaft below crankshaft.
2 valves per cylinder.
Digijet injection system.
Viable Red zone RPM: 5000rpm
Power
82 HP @ 4800rpm
Torque
105 ft/lbs @
2600rpm
Cruising speed
100 km/hour ( 62mph)
Maximum
passing speed
120 km/hour (75mph)
Approximate maximum speed
on steep grades
40-50 km/hour (27mph) in 2nd gear
Advantages, disadvantages, and explanation of the product.
Gas mileage (new!)
21 mpg highway
18 mpg city
(The
average mileage actually observed in a used motor is
on the order of 18-19 mpg.)
- The original engines (1.9 & 2.1 liter) are underpowered relative to the weight of the vehicle. Moreover, this type of engine is simply a paltry evolution beyond the Beetle's Type 1 motor. By keeping the engine at the rear of the Vanagon, VW reduced its engine options (motorization). The "boxer" engine is an engine with pushrods and camshaft at the base (an old design principle now out of use). Its greatest problem resides in the design of its head gaskets and seals with the engine block. With time, the surface of the heads corrodes eventually leaking coolant. The sealing of the upper and lower cylinders is another classic problem. The center of the engine is much more solid and reliable, so it is often possible to get away with a good resealing and a top-end (new AMC heads and pistons). This is the project we undertake most often at BJP. Now, what about the fuel injection systems (which in themselves include a plethora of expensive parts including the electronic computer unit, a fuel pump, AFM, idle stabilizer, fuel pressure regulator, injectors, etc.), the exhaust system, the alternator, and the starter? In a complete engine rebuilt, or even a partial one, it is essential to ensure that the rest of the components will be able to follow (and this is where costs may skyrocket). At BJP we will no longer consider re-using old heads, unless they are in perfect condition. Moreover, we cannot offer any guarantee when the client decides to retain the old heads. The AMC heads are not perfect, but they are new. With a little bit of work, they are more reliable than remanufactured VW heads. We give a tired old engine the best chance for a new life.
- Remanufacturing the heads: Even if no cracks are visible, there is a high risk of internal cracks appearing in the future. Particularly after having worked with the heads, the most critical cracks cause internal pressure in the cooling system, which can eventually lead to overheating of the engine. These cracks can also cause leaks in the combustion chambers, which lead to a poor running engine with inefficient combustion. Therefore, we no longer reuse old cylinder heads.
- A new power option is available: a European ECU (electronic computer unit) for the Digijet injection system. This computer does not require the signals from the Oxygen (O2) sensor, keeps the injector jets open longer, and maximizes the fuel injection efficiency in other ways. The approximate price of this ECU is $300.
- -The only advantage of keeping the original engine is for current resale value. Trends change, and Vanagons equipped with conversion engines are taking on value. Contrary to popular belief, small garages in the region have great fear of old VW engines, so you are no better off than with a conversion (unless a VW dealer is available). The core parts (case, crank, cams) are increasingly rare, and the end of their reliability is approaching. For example, the bypass coolant pipe for the 1.9L has been completely discontinued. Make no mistake; a well-maintained boxer can last a long time. The main problem is that these vehicles change hands often, and the maintenance often leaves much to be desired. The boxer with higher mileage becomes a high-maintenance engine.
- -Note on 1.9 and 2.1 liter engines: The 2.1 L is practically identical. It is the same engine block with very slight modifications. Only the crankshaft, the connecting rods and the pistons are different, and the stroke and the bore are slightly larger. The long block engines and the heads are interchangeable, but the injection is different. Not better, simply different. For my part, I consider the 2.1L to be a paltry evolution (yet again!) beyond the 1.9L.
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- The prices are very variable with a restoration of a VW engine, and require that the engine be removed from the engine compartment. Note that the estimated maximum cost derives from a comparison with conversion compared with the rebuild costs. The estimated minimum cost is based on the case in which it is not necessary to replace all of these parts. Does one need new pistons, new cylinder heads, new fuel injectors, a new alternator, etc.? Does the client require only a good resealing of the heads and replacement of a few small but critical parts?
- These boxer engines are at least twenty years, old, so it is important to understand that we cannot offer a fixed price for the repairs until the work is completed. We assure that we will always discuss the price with the client as the work proceeds to ensure that we know what client intend and agrees to change. The client is then responsible for their choices. All new parts are guaranteed for one year, as is the labor involved in installing them. If a part has not been replaced, the client is responsible for the price of both parts and labor. We insist on this, because sometimes it is worth replacing a part which will only cost a few dollars more, while we are inside the engine, rather than paying later to remove the engine or transmission again, which can take several hours. Moreover, it is sometimes more reliable to replace parts while the motor is out of the vehicle rather than doing it with the motor in place (for example, the exhaust system).
- For other vehicle problems unrelated to the motor (brakes, for example), BJP can furnish you parts and labor. As each vehicle is unique, we cannot explain this here, and the additional costs will be discussed individually.
Expected
lifespan of the engine block and the heads
after a complete rebuild
200,000 km /125k miles (engine block) and 75,000-200,00 km / 46- 124k miles (heads)
Guarantee
1 year on new parts and associated labor
Waiting time for parts
1 day to 1 week
Price of parts (estimated)
$500 (minimum) CAD
$3500 (maximum) CAD
Installation charge (estimated)
$900 (minimum) CAD
$1500 (maximum) CAD
Payable to:
Garage BJP
Saint-Hubert, PQ
Payable to:
Garage BJP
Saint-Hubert, PQ
Estimated total price (parts for fuel injection, clutch and exhaust system are not included)
$1400 (minimum)
$5000 (maximum)
Resale value
The value of these vehicles to some buyers cannot be estimated, as they may be of interest as collectors' items. Moreover, if you have a good rebuilt engine, unlike most sellers, you can justify a high price for your vehicle.
Some buyers may well not be looking for the higher power offered by the Subaru and BOSTIG motors. They will not be willing to pay extra simply because you, at a certain time, felt that extra power was worth the cost. If you only expect to drive a few thousand kilometers (say, 5,000) per year, this type of restoration is probably ideal for you. At 5,000 km per year, with regular maintenance, even after ten years you are not likely to have exhausted the life of the heads.
VW 2.1 (2100cc) 1986-1991
Horizontally opposed, water-cooled, 4 cylinder engine with hydraulic lifters. Pushrod actuated valves with gear driven camshaft below crankshaft.
2 valves per cylinder.
Digifant injection system.
Viable Red zone RPM: 5000rpm
Power
90HP @ 4800rpm
Torque
117 ft/lbs @ 3200rpm
Cruising speed
105-110 km/hour (65-70 mph)
Maximum pasing speed
125 km/hour (77 mph)
Maximum speed
on steep hills
45-55 km/hour in 2nd gear (28-35 mph)
Gas mileage (new!)
22 mpg highway
19 mpg city
(Average observed mileage on engines in use is about 19-20 mpg)
Expected lifespan of engine block and heads
200,000 km (blocK) and 75,000-200,00 km (heads) (in miles, same as 1.9L)
Guarantee
1 year for new parts and associated labor
Waiting time for parts
1 day to 1 week
Price of parts (estimated)
$500 (minimum) CAD
$4000 (maximum) CAD
Installation charge (estimated)
$900 (minimum) CAD
$1500 (maximum) CAD
Payable to:
Garage BJP
Saint-Hubert, PQ
Payable to:
Garage BJP
Saint-Hubert, PQ
Total price (estimated)
$1400 (minimum)
$5500 (maximum)
Resale value
Same as for the 1.9L
--------------- Motors and special parts - BJP Installation and VW parts -------
Advantages, disadvantages and explanation of the Subaru conversion products
First of all why do an engine conversion? I can answer with Why not? Or more power, more reliability and security, recent engine, modern mechanics and fuel injection system with modern diagnostics relying on the Onboard Diagnostic system (OBDII). All current vehicles use the OBDII computer to monitor the operations of the engine and any shop will be equipped to run the diagnostics utilizing this system to find the problems with the engine or the fuel injection system. You can now leverage and benefit from an almost perfect product. The conversion pioneers have already identified and worked around all the bugs for you.
- -The engine conversions are nothing new but date back many years. The first conversions can be traced back more than 20 years ago. At that time, it was rather a homemade conversion created by VW mechanics handy with tools and machining. Today with conversions becoming so popular, certain companies have provided mainstream products such as (Small Car and Kennedy Engineering Products) that have standardized the conversion work by manufacturing top quality parts. The conversion becomes easier and mostly more reliable.
- Next the evidence of the “Boxer” engine (horizontally opposed and flat engine) of the same design as the original VW but with modern components, with more power and reliability. This engine fits perfectly in the Vanagon engine bay with very little modifications. It should be understood that the majority of the engine tins and older fuel injection system will be remove to pave the way for the new Subaru engine. This engine is perfect and also rotates in the same direction. Although it is not well understood by the neophyte that we need to prep the engine bay and have all the ancillary parts ready for this conversion. This conversion, unfortunately takes more than just the engine: It requires that the donor Subaru be stripped of the wiring harness, the onboard computer and several other key components. Additionally we have to acquire all of the conversion components from several vendors. This is exactly what the folks have done. They offer a complete conversion kit for all Subaru engine type while adding their personal touch with the engine, the cooling component and the wiring harness.
- These engines can produce from 135 et 165 hp (for the Subaru 4 cylinders). The 2.2L finally provides a feeling of driving a “normal” Vanagon (Capability to merge into freeway traffic without fear of having enough power to move out of your own way. Being able to pass slower traffic in case of an emergency and able to accelerate pleasingly with a relaxed cruising speed). The 2.5L engine is almost too gutsy. This engine is quite impressive. You will find yourself having to throttle the power. Forget the the slow hill climbs, this engine has so much power that you will be able to speed up on the worst uphill climbs.
- The reputation and reliability of the Subaru engines is not to be outdone. The reliability of these engines are far from what they were back in the 80s. The 2.2L engine is an example of an extremely reliable engine. Many manufacturers of ultra-light airplanes have chosen this engine for its weight vs. power and its exemplary reliability. The SAAB corporation builds some of its current car line using the Subaru 2.5L engines
- The disadvantages are the prices that are still high, the resale value may still be unstable and unknown, the 2.2L are getting older and the fact that these conversions are still unknown to many mechanics and shops that may deal with your Vanagons
- The engines available have between 20,000km to 50,000km
- As an alternate option the Subaru 6-cylinder 3.3 liter engine creating 230hp, from an SVX model car is also available.
- The kit, currently does not come with the entire exhaust system. For the owners of the 2.1L Vanagons, this is not an issue since the stock muffler, catalytic converter and “J” pipe will be reused. On the other hand for the owners of a 1.9L Vanagon, it will be required to obtain these components. (Estimated: 500$)
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Subaru 2.5L (2500cc)
Horizontally opposed , water cooled 4 cylinder engine, with hydraulic valves, belt driven DOCH and SOCH overhead camshafts, and 4 valves per cylinder
Viable Red Zone RPM: 6500rpm
Power
167 HP
Torque
165 ft/lbs @ 4000rpm
Cruising speed
130 km/hour (70-80 mph)
Maximum passing speed
For overtaking vehicles
160+ km/hour (105+mph)
Maximum climbing speed
on steep grades
100+ km/hour in 4th gear (65 + mph)
Gasoline Consumption
20-22 mpg Highway
18 mpg City
Approximate Expected lifespan of the Subaru engine block and heads
300,000+ km (185k miles)
Guarantee
1 year
(engine and ancillary new parts
Waiting Time for ancillary parts
3 weeks to 1 month
(after pre-paying for the engine to the US Shop)
Price for ancillary parts
Starting from $7,600 CAD
Prix de l'installation
1 100 $ CAD
Estimated total price of the conversion
$8,700 CAD
(The price
is variable and depends on the cost of the transport and levied transfer
taxes payable to the government. The cost implies that
you have the engine and parts shipped but could be less if your pick them up
in the
Resale Value
The resale value is really favorable because the Subaru 2.5 Liter engine is much more powerful with a modern technology.
P.S. The topics and prices described here are only for general information, which may be subject to changes.