 Converting a Vanagon TB for use with 1.8 L-Jet, How I did it |
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| MrKona |
 Nov 2 2014, 08:36 PM
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#1
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Senior Member  Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None  |
There's currently a thread about using L-jet from a 1.8L engine for a 2.0 with discussion about using bigger bore throttle body from a later Vanagon.
I tried it but ran into an issue with the orientation of the flat on the shaft that engages the throttle body switch component used with L-Jet. Pictures are worth a thousand words, so here goes.. Here's the TPS and a picture of each TB with the plate in the throttle closed position. Original 1.8 L-jet on the right, Vanagon donor TB on the left. Notice the different orientation of the flat on the shafts. The flat engages a corresponding flat on the TPS. The flat on the Vanagon shaft is in the wrong position for the TPS. Attached image(s)    
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| MrKona |
Nov 2 2014, 08:44 PM
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#2
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
I didn't want to simply make a new flat on the bottom of the shaft where it engages the TPS because there is already a flat on the other side. That wouldn't leave much metal. Also, I think it would be difficult to exactly duplicate orientation of the factory flat. I put a multimeter to the TPS when it was installed on the TB and found that the switch engages pretty precisely at closed and WOT. I don't think I could duplicate that exact angle by eyeballing it on the bench grinder.
Attached thumbnail(s) 
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| MrKona |
Nov 2 2014, 08:48 PM
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#3
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
So I decided to use the shaft from the 1.8 TB. Only problem is that the recess in the shaft is sized for the smaller TB plate.
The 1.8 plate is 43mm in diameter, the vanagon plate is 48mm. Attached thumbnail(s)    Attached image(s) 
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| MrKona |
Nov 2 2014, 09:18 PM
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#4
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
So I decided the way to go was to lengthen the recess on the 1.8 TB shaft to fit the vanagon TB plate. 2.5mm on each side would do it. So I measured and taped it off to guide me with the bench grinder.
Attached image(s) 
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| Geezer914 |
Nov 2 2014, 09:20 PM
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#5
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Geezer914 Group: Members Posts: 1,789 Joined: 18-March 09 From: Salem, NJ Member No.: 10,179 Region Association: North East States 
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Great pictures! I just picked up a 2.1L throttle body on the Samba. (IMG:style_emoticons/default/piratenanner.gif)
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| MrKona |
Nov 2 2014, 09:24 PM
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#6
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
Brief intermission, and on a related note.. another one of my hobbies is vintage shop machines. My bench grinder is a 1962 Sears Craftsman that I rescued a few years ago and restored to it's former glory (and back to original colors).
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| MrKona |
Nov 2 2014, 09:27 PM
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#7
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
Five minutes of careful grinding on each side was all it needed. What a great thing that VW/Porsche used the same spacing between holes for both TB plates.
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| MrKona |
Nov 2 2014, 09:31 PM
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#8
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
And with that, I inserted the modified shaft in the Vanagon TB, attached the plate, assembled the spring mechanism... and I now have an enlarged TB that will fit the 1.8 L-jet system (for use on my 2.0 engine).
Attached thumbnail(s)  Attached image(s)  
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| MrKona |
Nov 2 2014, 09:34 PM
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#9
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
One more note, you may have noticed already that there is a casting difference between the original TB and Vanagon TB where the TPS attaches. It feels pretty well anchored with one screw and of course the shaft that inserts into the TPS. Just for good measure, I put a zip tie around the non-screwed end and the vacuum port. I doubt it's needed, but it's just added assurance.
Attached image(s)  
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| rick 918-S |
Nov 2 2014, 09:50 PM
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#10
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Hey nice rack! -Celette Group: Members Posts: 20,816 Joined: 30-December 02 From: Now in Superior WI Member No.: 43 Region Association: Northstar Region 
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Nice work. Way to think out of the box.
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| Dave_Darling |
Nov 3 2014, 12:29 AM
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#11
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914 Idiot Group: Members Posts: 15,063 Joined: 9-January 03 From: Silicon Valley / Kailua-Kona Member No.: 121 Region Association: Northern California
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Peen or use Loctite on the throttle plate screws. You don't want one of them to fall out...
--DD |
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| MrKona |
Nov 3 2014, 01:47 AM
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#12
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
QUOTE(Dave_Darling @ Nov 2 2014, 10:29 PM)  Peen or use Loctite on the throttle plate screws. You don't want one of them to fall out... --DD Dave - thanks for the reminder. I'll peen them. |
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| Valy |
Nov 3 2014, 02:11 AM
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#13
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
Did you try to use the vanagon throttle switch?
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| MrKona |
Nov 3 2014, 09:16 AM
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#14
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
QUOTE(Valy @ Nov 3 2014, 12:11 AM) Did you try to use the vanagon throttle switch? No. There are two terminals on the Vanagon switch, and three on the l-jet, hence the wiring harness would need work. Didn't want to open that can of worms. |
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| Root_Werks |
Nov 3 2014, 09:43 AM
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#15
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Village Idiot Group: Members Posts: 8,505 Joined: 25-May 04 From: About 5NM from Canada Member No.: 2,105 Region Association: Pacific Northwest
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Really good write up and something I would have used on a L-Jet 2.0 a few years back. Well done!
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| Valy |
Nov 3 2014, 02:14 PM
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#16
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Senior Member Group: Members Posts: 1,677 Joined: 6-April 10 From: Sunnyvale, CA Member No.: 11,573 Region Association: Northern California |
QUOTE(MrKona @ Nov 3 2014, 08:16 AM) QUOTE(Valy @ Nov 3 2014, 12:11 AM) Did you try to use the vanagon throttle switch? No. There are two terminals on the Vanagon switch, and three on the l-jet, hence the wiring harness would need work. Didn't want to open that can of worms. Thanks! Does the bigger TB fit the rubber boot from the AFM? |
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| pilothyer |
Nov 3 2014, 02:32 PM
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#17
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Member Group: Members Posts: 838 Joined: 21-May 08 From: N. Alabama Member No.: 9,080 Region Association: South East States |
Bryan Do you have the part number for this throttle body? also Would one from a 1.9 work or is there a difference in dimension? Thanks for a reply
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| MrKona |
Nov 3 2014, 10:46 PM
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#18
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
QUOTE(Valy @ Nov 3 2014, 12:14 PM) QUOTE(MrKona @ Nov 3 2014, 08:16 AM) QUOTE(Valy @ Nov 3 2014, 12:11 AM) Did you try to use the vanagon throttle switch? No. There are two terminals on the Vanagon switch, and three on the l-jet, hence the wiring harness would need work. Didn't want to open that can of worms. Thanks! Does the bigger TB fit the rubber boot from the AFM? It sure does! The beautiful thing is that the outer diameter is the same on both. Here's a picture, Vanagon TB on the left, L-Jet TB on the right. Attached image(s) 
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| MrKona |
Nov 3 2014, 10:59 PM
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#19
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Senior Member Group: Members Posts: 597 Joined: 25-July 05 From: Santa Rosa, CA Member No.: 4,469 Region Association: None |
QUOTE(pilothyer @ Nov 3 2014, 12:32 PM) Bryan Do you have the part number for this throttle body? also Would one from a 1.9 work or is there a difference in dimension? Thanks for a reply The p/n for the late model, 2.1 Vanagon is 025 133 067. The earlier 1.9 Vanagon TB is 45mm, the same as the 1.8 L-jet TB. I only know this from the experience of removing one from a 1.9L only to find it was 45mm diameter. |
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| type47 |
Nov 4 2014, 06:15 AM
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#20
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Viermeister Group: Members Posts: 4,254 Joined: 7-August 03 From: Vienna, VA Member No.: 994 Region Association: MidAtlantic Region |
I wonder what is the size of the TB for the 912E. But finding one ... (IMG:style_emoticons/default/wacko.gif)
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