You don't need the wiring, exhaust, etc., sell that on www.thesamba.com.
Just think of it as a 1.9 with a different water pump (change it to the 1.9
type), an oil cooler that won't fit, a better starter (if you got it) and
maybe a different intake system.

That's a good write up by the Old Volks Home, but since you are dropping in
a used engine forget about some of the prep. I mounted the oil cooler
remotely behind the left tail light when I did this on my '84 in 1999, but
it's not worth the trouble.  Lots of plumbing plus tapping for a couple of
nipples on the water pump and elsewhere.  It was also a PITA to change the
filter.

I'd also stick with the correct stock 87 degree T-stat, 190F is where this
engine is supposed to run and pro guru Dennis Haynes agrees:  "The correct
t-stat for the vanagon is 87C and there is no reason, benefit, or advantage
to use different ones for summer/winter. The correct stat will have a small
lower, (bypass) disc with a step in it. The top disc will also have a rubber
seal (not talking about the O-ring seal), to ensure no bypass when closed.
There should not be any bypass or bleed hole. I miss the dealer ones. The
aftermarket including so called German ones do not have the consistency.
Note that if you get a stat from almost any local parts store you will
probably get the wrong one. Check the lower disc very carefully."  --Dennis
Haynes, 1/19/2014

I'd also recommend installing an oil pressure gauge to avoid blowing this
engine up, and you'll want it on your conversion anyway.  It happens a lot
with the 2.1: http://volksweb.relitech.com/21rodbrg.htm  The
Subaruvanagon.com list just got a new member today because of this.  You can
sell this engine when you do your conversion if you don't blow it up.

It's an easy swap, just keep it simple and cheap since it's temporary.

Stuart
Two 1.9s and two 2.1s in my past (all in early vans); Subaru in my future

-----Original Message-----
Subject: 1.9l WBX to 2.1l WBX Swap Tips?

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"