Subaru EJ22 in the Flatback Bug...

[Joel]

[Nepenthe88]

^^^ gonna do a Rebuild or Subarugears ??
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a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
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[Nepenthe88]

and... I dropped some cash down the black hole today This is the most expensive part of the conversion, hands down so I'm glad it's not still staring me in the face. Made 3 purchases for a grand total of $675 (with free shipping ):

#1- Kennedy EJ22/EJ25 to VW Bug Adapter Plate with 200mm flywheel ($475)
http://www.pacificcustoms.com/KEPSUBARU002-200.html

#2- Kennedy Stage 2 Pressure plate, 6 puck clutch disk and late throw out ($197)
http://www.pacificcustoms.com/mm5/merchant.mvc?Screen=PROD&Product_Code=AC141928

#3- Clutch Alignment Tool ($3). I didn't use anything last time I did a clutch, but for $3, Why not?
http://www.pacificcustoms.com/mm5/merchant.mvc?Scr...ange_high=

my current cost of the project is as follows:
+$200 for the donor subaru
+$10 for the oil filler neck
+$29 for wiring harness supplies
+$7 for the VSS sensor
+$681 for adapter/ clutch kit ***edited to include clutch install hardware***

-$15 for the remote start

.........= $912 total
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a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
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[Ghia Nut]

just tagging myself in this post so I can read it later, awesome work man, gotta get my wiring together.
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'59 typ1 rajay turbo
'72 Ghia rajay 1641 dual 36DRLAs, 1 3/8" SS merged header and fat boy
78" GL Vert with ej22t swap
This will likely change tomorrow to something else.

[Nepenthe88]

@ghianut.. I hear ya. Once things calm down a bit im gonna draw up a nice wiring diagram, so stay tuned.

Also... Test drove a 2004 subee Forester xt today. Ooh baby! She was a sleeper. Once that turbo spools, youre off! She'd be awesome in a bug/bus. Regardless, I'm looking for a winter 'beater' that I can turn into a donor in a year or two. It's really gotta be the right car at the right price though.
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a Black & Blue Su-BUS-aroo

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[JasonBaker]

aren't you going to need the pilot bearing???

http://www.pacificcustoms.com/mm5/merchant.mvc?Scr...d_products

[Nepenthe88]

[Nepenthe88]

... that phone call did cost me an extra $6 though I wound up getting some clutch installation hardware added to the order. Metric stuff can sometimes be difficult to find in the right pitch / length and it sure isn't worth my time driving around wasting gas searching for 6 grade 8.8 bolts and wobble washers. I'll edit my expenses now so I don't forget. Also, here's a link to the hardware:

http://www.pacificcustoms.com/AC000806.html
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a Black & Blue Su-BUS-aroo

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[Nepenthe88]

While I was out and about looking at Subee's, I also stopped at the Subaru Dealer's Parts Department to get a line on how much a complete gasket kit would go for. Dealer want's $309 for their kit, which is obviously all guaranteed to be OEM Subaru stuff. Here's the printout of what it includes:

Now, after trolling various subee swap threads, it seems like pretty conventional wisdom that you MUST go with the BROWN OEM subaru seals, as the more generic black ones tend to leak pretty quickly. I don't know about you, but I'd rather do the job once than mess around with crappy parts and have to pull the engine 3 or 4 times replacing various failed seals... Despite the fact that you can get a complete EJ22 gasket kit for right around $38 (?!).

That said, the question I'd like to pose is... Does anyone know where to get a quality OEM seal kit, without paying the dealer's markup???

One would think that a quick google-ing would answer the question, but....buyer beware?! As I found this "Complete OEM Gasket Kit" for a mere $280, but (by the looks of things) all their seals are BLACK?! here's that link:
http://www.cimotorsports.net/motor-sport-products/subaru-oem-complete-gasket-kit-ej22.html

I realize I might have to go troll the subaru forums to get an answer, but thought I'd throw it out there anyway
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a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
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[Ghia Nut]

Wiring diagram for the swap...
http://www.main.experiencetherave.com/subaru_manual_scans/FSM_Scans/Subaru_2.2L_Wiring_Diag.pdf

If you have any additions or changes suggest it man.

Also all the factory service manuals etc
http://shoptalkforums.com/viewtopic.php?f=19&t=138510
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'59 typ1 rajay turbo
'72 Ghia rajay 1641 dual 36DRLAs, 1 3/8" SS merged header and fat boy
78" GL Vert with ej22t swap
This will likely change tomorrow to something else.

[Nepenthe88]

@GhiaNut-- Hey, that's a nice find. I hadn't run across that diagram yet. The only issue I have with it is that it's A) visually complicated, and B) isn't quite "complete".

As far as A) goes, I'd really like to break that master diagram into smaller "systems". One for Ignition, another for diagnostics, a third for the O2 sensor, etc. It may get a little repetitive, but I think it will be worth it in the long run. Not only will other people be able to check their work system by system, but People should be able to troubleshoot future electrical issues easier in the future.

As far as B) goes, I think it would be beneficial to really idiot-proof everything and show pictures / diagrams of all the quick clip connectors and relays wired up (I also want to have a little information on troubleshooting / testing relays in general)

Now, this isn't really my idea. I re-wired the entire bug with a Watson Streetworks harness and not only did that company supply me with a nice master wiring diagram and individual "systems" diagrams, but there's also a thread on here that's helping to flesh out some of the fuzzier parts of those documents. You can visit that thread here, and see one of the diagrams I did on pg.5 I'm hoping to do something similar (visually) with the subaru wiring. It's a different animal of course, so a slightly different visual technique is going to have to be used. Right now I'm thinking.... a black and white master @ 25% opacity (to show the general relation of the parts to the whole) with the system in question in full color to jump out.. if that makes sense

http://www.thesamba.com/vw/forum/viewtopic.php?t=5...p;start=80
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a Black & Blue Su-BUS-aroo

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[madness726]

Joel sent me a link to your build post, Nice job so far.. I just started mine.. I wish I would have labeled the wiring harness but I did not because I figured I would just send it out to be done... OOPS I will follow your post to see what happens..
Also here is a link to mine..

http://forums.aussieveedubbers.com/viewtopic.php?tid=97861

[Nepenthe88]

@Madness-- I see you've a '93 Subee as well. Very nice year.... for a donor! I wish I woulda went subee powered straight out the gate-- you must be smarter than me! Doing it from the get-go will give you a chance to have everything buttoned up and painted nice the first time around. Might I suggest a removable rear apron (Joel's way, not mine), some Ghia disks up front (at minimum), and you should probably take a look at the FOAM link in my sig. It's good reading for anyone that's got a fatchick with a bubbling C.

That is all for now grasshopper. You've been bookmarked. I'll be watching
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[surfbeetle]

Have you tried http://www.outfrontmotorsports.com ? I ordered some exhaust gaskets and small stuff from them. They really know their stuff.
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67 Beetle Build Thread
69 Beetle

[Joel]

[Ghia Nut]

wish I could do a subagears swap, but sooooo expensive.
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'59 typ1 rajay turbo
'72 Ghia rajay 1641 dual 36DRLAs, 1 3/8" SS merged header and fat boy
78" GL Vert with ej22t swap
This will likely change tomorrow to something else.

[JasonBaker]

[Nepenthe88]

^^ Thanks again. I looked up the Topline Gaskets but couldn't really find much info on them (which always makes me leery). I did however stumble onto a good tidbit of info while I was searching....

Two companies (ISHINO and NIPPON REINZ) make gasket kits with OEM seals (according to a Subaru forum and one of the vendors... as always, buyer beware, I have no experience with these manufacturers/ vendors). I found a good deal on a NIPPON kit for $140. Only problem is it didn't have a parts list of what's included (I'm risk adverse and wish venders would spec out everything in their kit, as opposed to merely calling it a "Kit" ...seems silly to me). Here's a link. moving back one page you'll see "This is a OEM Product" (sic) in red writing (in case the link dies, it looks like we're looking for AutoPart# W0133-1609342 as that # is the same for both ISHINO and NIPPON 2.2L "kit"): http://www.autopartsnetwork.com/catalog/1995/Subar...year:1995_

Regardless, I also heard good stuff about an Ebay vender named Domestic Gaskets that uses all OEM seals. I didn't see an EJ22 kit. Maybe they're sold out? I did however find a halfway reasonable Serpentine belt kit with all the pulleys (and brown seals ). They come in different package configurations too. With water pump / without. With tensioner / without. It's nice to know you can customize their "kits" to include exactly what you need.http://stores.ebay.com/domesticgaskets/_i.html?_nkw=2.2L+subaru&submit=Search&_sid=493876738

Regardless, I'm not buying anything until I can pressure wash the engine. I want to get everything clean and bolt on the adapter (which is on the way already! got a tracking # last night-- For free shipping, I'm impressed, WOW!). After that I want to bolt it to the back of the Domus Flatback bug truck (also on the way) and get it to run for a little while to see if there's any noticeable leaks. I feel like this has a couple benefits:

#1, the Domus Flatback has a "baja" style open rear end, so it should be easy to bolt in / bolt out.
#2, I'll have all sorts of room to poke things while the engine's in the car because it's even more OPEN than a baja.
#3, A complete car makes a better test stand than any homebrew test stand I could fab up.
#4.... it's a FLATBACK bug, which in my mind is basically a large, flat, movable workbench
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[Oakley Diesel]

Are their any dowel pins on your case ? or do they stay with the transmission? Their are 2 holes for dowels on my case & holes in the adapter. But my engine did not come with any.
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Let my name be Feared at the gates of Hell as I exault the Savior!!
72 Super EJ20 turbo install in progress!
04 Excursion 6.0 w/ Spartan tunes

[ts39136]

Nice to see your making progress. One recommendation from experience, ditch the six puck and go for a full circle clutch disc. PC sold me on the six-puck, too, but it's much to grabby on the street IMO. I'm running 32" tires with an 002 and the full circle clutch and stage ii plate are working fine.

Keep up the good work. I like your detailed documentation.
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