Date:         Tue, 21 Sep 1999 00:59:19 -0700
Reply-To:     Randolph Feuerriegel <RFeuerriegel@BC.SYMPATICO.CA>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Randolph Feuerriegel <RFeuerriegel@BC.SYMPATICO.CA>
Subject:      2.0L Conversion 5K update, longish
Content-Type: text/plain; charset=us-ascii

Greetings all.

For those who are thinking about engine conversions, I thought that a
5000 Km review would be of interest. While not a long term review by any
means it might offer some insight to those contemplating the swap. First
off, no regrets. If the WBX were more reliable to me, less expensive to
fix, and a bit more power I might not have gone this route. The WBX was
not trashed, just showing its age but still had some resale value.
Having owned numerous VW's in the past, I had forgotten how torquey an
8V engine is. Its alot of fun. The Audi 2.0L in my syncro has about the
same torque as the WBX did in the lower rpm range, but get it up over
4000, it really sings. Even in 4th gear there is pull. It happily runs
up to 6000 rpm, probably more, my tach can't show it. For the first time
I had the van up over 150 Km/h, previous top speed 137 km/h. Its
very comfortable cruising at 100 to 120 km/h, spinning at about 4000
rpm.
My hwy mileage has improved from 13 litres per 100 Km to 11 litres. City
is higher. That translates to about 25 mpg(Imp), 21.5 US gal.
The engine is out of Audi 80, 2.0L, stamped on the block, has about
120,000 km on it, and I expect it to go for quite awhile. FI is CIS-E
with knock sensor, o2 sensor, but not Motronic.
I purchased the FastForward basic kit(adapter, flywheel & crossmember),
plus David did the wiring harness/fuel pump relay from one I supplied so
it becomes almost a plug and play. I also purchased the platform for the
coolant reservoir and airbox. The new crossmember is a simple bolt on,
engine sits at a 15 degree angle which also means the deck lid has to be
modified a few inches. There is no loss of ground clearance and my skid
plate fits fine. Actually, I did put in a 3/8" shim to drop the old
crossmember down as to avoid hitting the p/s pump. The p/s reservoir
does not have to be moved, but I did find one hose a bit of a stretch.
Found an Audi p/s hose with same fitting only longer. The exhaust system
was fabricated locally, a 2 into 1 down pipe, cat and a free flowing 6"
dia. canister type muffler. Stock WBX cat, I could have used the stock
WBX muffler, but it is quite restrictive. Admittedly, I miss the off
beat idle of the WBX, but this engine with the throttle on at 4500 rpm
and up has a decent growl to it. I did have a few vibration problems
with the new exhaust(hanger issue)but that is pretty much sorted. Engine
noise is not quite sorted yet, my modified lid needs insulation, but I
have had the lid covered with stuff and found the noise level no
different than the WBX. Just a different tune.
In the long run this setup for me should be cost effective, parts at
FLARS are in abundance and cheap, hey, in a few years the 1.8T will be
available used, should almost bolt right in! (a bit more work).
If you are planning on doing a conversion with a used engine, try to get
everything you need from one good donor vehicle. Can save you a few
headaches.
Engine bay aesthetics is what you make of it, hoses, wiring etc. Mine
does not have the "factory look", but it comes pretty close.
The cost of this conversion was roughly 4000.00 Cdn., compared to
7000.00 Cdn. plus install, for a "factory fit". I sold the WBX for
1400.00 Cdn. which offset some of the cost. Over all I am quite pleased
with the swap, pleased with FastForwards conversion kit and with David's
assistance.
A few other observations to note, the increased power is reminding me to
get the brakes done, maybe upgrade to vented discs. My worn shocks are
showing more so now, so that it is the works soon, rears done. Checking
the oil means lifting the deck lid, a minor inconvenience. On the other
hand, engine maintenace is easier than the WBX. Thats it for now, feel
free to drop me line if want to know more about the swap.
Take care.
--
R.Feuerriegel
88 syncro