My 1.6 VW engine is getting tired, so I have to do something. I have the choice between rebuilding my engine, buy a rebuild engine, OR swap the engine to a watercooled one. Because the first to options where quite expensive AND the quality of engine parts and rebuilds is getting worse, I decided for the watercooled one. It will cost me roughly the same (maybe a little less) then the vw engine, but I would gain horsepower, smoother running (fuel injection) and it will produce less engine noise. Plus I would have a heater without a slight smell of exhaust fumes. Another plus would be running the beetle on the freeway at 120 km/h knowing that this engine should be able to do this without problems.
I decided to convert to an Alfa Romeo engine. Why? See the first link in my to-do list:
The To-Do list:
Not entirely in chronological order…
choose and buy an engine
create an engine trolley
replace old and worn rubber gearbox mountings
buy adapter kit (from DS-tuning)
fit engine to the engine bay, I’ll have to cut away (part of) the bumper brackets.
At first I had the radiator in the back, but this didn’t work on the highway (read more about it here). Now I am putting the radiator in the front.
add parcel shelf area to engine room
place the header tank & create/attach the coolant lines
find a place for the heater and it’s hoses and ducting
run coolant pipes from front to back
fabricate return inlet, place the fuel pump and an injection fuel filter
buy workshop manual for Alfa Romeo 33 1990-1994
wire-up a temperature-gauge, rev-counter and indicator lights
connect throttle cable to Alfa throttle cable
find an alternative for the standard airfilter
create an exhaust
create brackets for the rear engine support and rear apron
perform basic maintenance on engine
After all the modifications, this is how you install the Alfa engine (engine start at the end of the clip):
Running smoothly for the first time, on 2007-04-30: