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Subject:1.9l WBX to 2.1l WBX Swap Tips?
From:C B
Date:Tue, 21 Jan 2014 15:47:29 -0800

Since Cunegonde's 1.9l WBX is not too happy after an oil overfill, I have
located a 1990 2.1l WBX replacement. It comes with the newer Bosch fuel
injection set-up.

What do I need to know about the swap?
What consumables will I need? Gaskets, bolts, hoses/clamps,
wires/connectors, sealants, liquids (aside from fresh coolant)?
Mechanical fit issues?
Will the existing 4-speed manual transmission mate correctly, and is it
appropriately geared?
Remove/insert from above or below? (I'm working at home, no lift, but lots
of ramps and multiple hydraulic jacks)
Will I need the 2.1l exhaust headers, transverse pipes, c-pipe or muffler?
Exhaust brackets different?
Engine mounts/bed rail fitting issues?
1.9l starter re-use issues?
1.9l alternator re-use?
1.9l waterpump (I have a new spare)?
Attaching and setting up the new FI system necessary? My original ECU has
never caused Vanagon syndrome, but as we all know is neither fuel-efficient
nor provides much HP.
1.9l airbox/filter OK?
Other sensor or wiring harness details I should know?
I have an aftermarket tach on the '83.5 speedo-clock-type dash instruments.
Is is connected any differently on the 2.1l?
Anything I've missed?

Oh, and this is temporary - a season or two while I source a modern VW
inline-4 and save my pennies for a (custom?) transmission to match it. I'll
tackle those questions in the next email.

--
Bretts

1983 1.9l WBX Ivory Westfalia "Cunegonde"

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