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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Sat Oct 24, 2009 12:29 pm Post subject: 2.5 SOHC Conversion Journal |
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What the heck sure some might find this interesting. Got a 2.5 out of a 2001 Legacy 90k ran great. Replaced head gaskets, VCG, Plug Gaskets, VCG Bolt seals, cam and crank seals, dipstick tube o-rings, Fill tube o-ring, Oil pump o-ring and re-seal, Coolant manifold o-rings, T-Belt, ALL Rollers, W-Pump, T-Stat, Ten asm... sure I missed some stuff but you get the point, the inside of that engine was VERY CLEAN well maintained. Sorry no pictures of the engine rebuild not that exciting. (Oh and what about that torque sequence for the head bolts... torque torque loosen loosen torque torque etc.. huh weird I thought?) Placed smallcar order for bellhousing, Stage 2 clutch, VSS, ECM Chip, and couple other small things. I am going to use smallcar bellhousing along with Rocky Mountain Westy engine carrier, exhaust, coolant pipes, P/S hoses etc. Think this will turn out pretty nice, I am pretty sold on the bellhousing or else I would have gone 100% RMW, IMO you just can't beet there quality and level of support A+ crew!! I'll be working on my harness this week and will be posting some pictures along with that.
Schony _________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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climberjohn Samba Member
Joined: January 11, 2005 Posts: 1840 Location: Portland Orygun
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Posted: Sun Oct 25, 2009 10:01 am Post subject: |
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Sounds good, keep us posted! _________________ '86 Westy, 2.5 Subaru power
Know your limits. Exceed them often. |
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Escorial Syncro Samba Member
Joined: May 02, 2004 Posts: 436 Location: Manitou Springs, CO
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Posted: Sun Oct 25, 2009 10:13 am Post subject: |
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Does the RMW carrier fit with the Small Car bellhousing? I thought there was some issue where the bellhousing moves the motor more forward in the engine bay? Maybe I'm wrong, just going from memory. But curious none the less because I thought the RMW was designed with an adapter plate in mind. _________________ Joel Lane
1985 Vanagon converted to syncro, ALH TDI, Reimo Primus top with Westy interior
2002 Toyota Tundra 4x4
1974 Honda CL360 Scrambler (for sale!) |
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Rhinoculips Samba Member
Joined: August 08, 2005 Posts: 918 Location: Keystone, Colorado
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Posted: Sun Oct 25, 2009 1:02 pm Post subject: |
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joeldella wrote: |
Does the RMW carrier fit with the Small Car bellhousing? I thought there was some issue where the bellhousing moves the motor more forward in the engine bay? Maybe I'm wrong, just going from memory. But curious none the less because I thought the RMW was designed with an adapter plate in mind. |
From what I understand, the SC bellhousing keeps the engine in the same location as if it were installed with an adapter plate. _________________ “May your trails be crooked, winding, lonesome, dangerous, leading to the most amazing view. May your mountains rise into and above the clouds.” - Edward Abbey
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Fri Nov 13, 2009 2:10 pm Post subject: |
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OK So I got half my parts here are some pictures. Small Car bellhousing kit Stage 2.5 clutch/pp/fly, speed sensor. All parts look very good quality. I am now working on my harness and wow what a job, I have about 7.5 hours into it now and have probably 3 to 4 more to go. When doing this harness I STRONGLY suggest getting a good pair of Dykes I started off using a pair of MAC's that came with a kit and they suck, Went back to work and got my Knipex long dykes and was much better. I have BLISTERS on my hands from doing this wiring lol. I will post some pictures of the wiring this weekend sorry don't have any pictures of harness before I started .... was just a full subaru car harness nothing special. Oh and did I mention what a PITA it is to get this thing organized!?!? Should have my RMW parts by end of the month, i'll keep ya posted. _________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Fri Nov 13, 2009 2:15 pm Post subject: |
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forgot about the pictures LOL
Yes I know the motor isn't 100% back together but u get the point _________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Sat Dec 05, 2009 7:40 pm Post subject: |
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Been going good, just taking my time been busy at work. So I got the harness done I think it looks pretty good and am confident it's all correct. The one thing I am wondering is if it's to fat in the center... it's about 2". It was a pretty tight fit getting that stock harness out today, that tin behind the "black box" is sort of a PITA seams that maybe I should notch that a little bit to avoid that bend? Another thing what is the section of harness that goes up behind the left C piller used for? And how about the black C/M behind the right tail light? Here's a few of the harness work, will post some engine removal photos early next week.
_________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Sat Dec 05, 2009 7:42 pm Post subject: |
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couple more
_________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Sat Dec 05, 2009 8:35 pm Post subject: |
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What I was going for....
_________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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purplepeopleeater Samba Member
Joined: July 23, 2005 Posts: 3117 Location: E. Washington
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Posted: Sat Dec 05, 2009 9:00 pm Post subject: |
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wow nice, want to do my harness next? |
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Rubber Tramp Samba Member
Joined: October 07, 2008 Posts: 385 Location: DFW, Texas
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Posted: Sat Dec 05, 2009 10:14 pm Post subject: |
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Good job man! Everything looks great so far, keep it up!
The RMW crew is some awesome guys to do business with huh? I'm having a great experience with them. My svx conversion parts got packed up and shipped yesterday, should be getting them very soon _________________ 1985 SVX powered Westy - soon to be converted to syncro
http://www.thesamba.com/vw/forum/viewtopic.php?t=382910
^^^Rocky Mountain Westy SVX rebuild and conversion^^^ |
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Sun Dec 06, 2009 8:33 am Post subject: |
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Thanks, and yes they are very cool. I think I may have saw your conversion parts all laid out yesterday while I was in there talking with Mike. Guess he's got a CNC Plasma table on the way, i'm sure they'll be getting creative with that . Think I figured out what those sections of wiring where for, behind the right tail is the Idle air control box I think, and the wires going up threw left c pillar are for my A/C and blower. _________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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ftp2leta Samba Member
Joined: October 11, 2004 Posts: 3271 Location: Montreal
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Sun Dec 06, 2009 3:02 pm Post subject: |
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Quote: |
Hi hi hi, in a good way
Ben |
What do you mean... don't get it? It's to fat, going to be a PITA er what? Never done this b4. _________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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ftp2leta Samba Member
Joined: October 11, 2004 Posts: 3271 Location: Montreal
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Posted: Sun Dec 06, 2009 3:38 pm Post subject: |
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vwkelso wrote: |
Quote: |
Hi hi hi, in a good way
Ben |
What do you mean... don't get it? It's to fat, going to be a PITA er what? Never done this b4. |
Just kidding, well, 2in is a bit on the FAT side
But wires are wires, the way you routed them is the reason it's a bit big, but that won't affect at all the operation.
It all depend where you put the ECM/ECU and the way you route OS wire and bla bla bla...
Your doing a great job. I have great respect for DIY.
I see nothing wrong with your conversion so far, keep the picture coming, if you have any question i will follow your thread.
Here is a picture of an 03:
On those i route the OS wire separately because my ECM goes behind the right tail light.
Another shot, in this case junction box harness and main harness are together.
Cheers, Ben _________________ Working with rust, grease, dirt and dust is a sad truth.
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FI part for sale: http://www.benplace.com/parts_sale1.htm
My site: http://www.benplace.com/vw2.htm
Subi conversion: http://www.benplace.com/vanaru_eng.htm
Youtube http://www.youtube.com/user/ftp2leta |
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Sun Dec 06, 2009 4:19 pm Post subject: |
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Cool thanks man, On your harness the center wire with the red rubber stud cover, blue connector and small gray connector this is the Alt and A/C connector right? I don't have the alt post terminal on mine... is this positive for ECM, why dose alt go to ECM? I hope I added a prevision for this with my To Vanagon wires.
And on hindsight I should have considered the behind R/T light for the ECM location. I think I might have to do a little cutting to that tin behind the black box and maybe make the hole under the seat a little bigger.
The next step as of today is to figure out the vanagon wiring. The Engine harness is out, just need to figure out what's what of the leftover.
Schony
Oh and I like your web page, informative, looks like you've got a lot of nice job's under your belt! _________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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ftp2leta Samba Member
Joined: October 11, 2004 Posts: 3271 Location: Montreal
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Posted: Mon Dec 07, 2009 6:34 am Post subject: |
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Hi and thanks.
Yes it is (center wire)
Power from ALT goes to Relay (relay and ECM are together in a sealed box), IGN + from junction box to fuel pump relay AND ECM, but it's been a wile that i did an 00-01 Still, it's always the same principle.
In the VW harness you need to keep the rounded connector that was in the black junction box, it as several wire but i don't use them all. But again, it all depend on YOUR setup.
But i'll tell you the major one (in junction box and not on harness):
Single yellow connector with black wire is: Ignition + (often as a 5 amp fuse), goes to ECM and fuel pump relay
Single yellow connector with blue wire is: ALT light in dash, this need to go to ALT directly (grey or green plug).
Main rounded connector:
Yellow/red is: temperature gauge in cluster, goes on the reverse manifold temp sender. If you use the Subi sender you need a .28 OHM resistor.
Red/black is: Your Start Signal, goes to ECM
Green / w shield OR blue/w black on earllier model is: Oil pressure, this wire can be found in main harness but very close to engine main plug
Green is: RPM, goes to ECM
Bizarre blue green/blue is: Expansion tank sender.
Brown is a ground, i don't use it, it's old and always give me problem, i built my own ground.
Yellow center of plug is: I don't remember and never use this one.
So, find the female side of the plug in the harness and the EX tank plug and wire. That is all you need in the old harness.
Ben _________________ Working with rust, grease, dirt and dust is a sad truth.
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FI part for sale: http://www.benplace.com/parts_sale1.htm
My site: http://www.benplace.com/vw2.htm
Subi conversion: http://www.benplace.com/vanaru_eng.htm
Youtube http://www.youtube.com/user/ftp2leta |
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Mon Dec 07, 2009 11:15 am Post subject: |
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Some engine removal pic's.
_________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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vwkelso Samba Member
Joined: September 09, 2005 Posts: 133 Location: Northern Colorado
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Posted: Mon Dec 07, 2009 11:16 am Post subject: |
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Oh and a quick question... Do I remove the tins around the engine bay for the subie motor? Or do I just leave them alone? _________________ 86 Syncro
73 Westy
69 Sand Chariots Vaquero |
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ftp2leta Samba Member
Joined: October 11, 2004 Posts: 3271 Location: Montreal
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