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ShultzRoadHouse
Samba Member
Joined: March 28, 2011
Posts: 318
Location: Caldwell, ID
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 Posted: Wed Jun 04, 2014 3:21 pm Post subject: Aircooled to EJ22 Conversion |
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Well I took the plunge and I purchased a '93 Subaru Legacy from the Copart auction site last weekend. The engine has 141,000 on the ODO and it started up great and ran so smooth. I also plan on purchasing the RMW conversion kit and having maybe having them do the harness. I am in the process of aquiring all the cooling bits (radiator, coolant lines, fan) as I hope to be starting the conversion in the fall.
My question is, can Rocky Mountain Westy modify the harness to work with the aircooled Van or is the modified harness specificly modified for the '83 and later Vans? I hear that a guy named Tom Sheils does excellent harness work but does Tom do custum harness modifications for aircooled Vans? I know finding all the bits might take a while (& money) but info for converting an aircooled Van is pretty scarce. Can anyone with experience or any of you know where to point me for searching out this info. I haven't talked with Mike @ Rocky Mountain Westy yet but information is very limited for the aircooled to EJ22 conversion. I have rebuilt the 2.0 that is in it and have also rebuilt the 1600 thats in my super beetle so im not new to engines.
The subaru arrives today and I will start the engine and harness removal this weekend. I will use this thread to start my conversion process so any other aircooled Van owners might have some more info for theirs. This Van is super important to my wife and I so just buying a water cooled Van is not an option. I have some funds set aside for this project as I know it will be a more involved process. So please, any help or info will be appreciated. Thanks,
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ShultzRoadHouse
'81 AirCooled Westy RIP
'82 Westy w/ '93 Subaru EJ22
'71 Super Beetle w/ '75 AJ 1600
'12 Jetta |
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dreweast
Samba Member
Joined: March 20, 2010
Posts: 26
Location: Sandbar, Eastern Canada
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| Posted: Wed Jun 04, 2014 3:41 pm Post subject: |
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I took on this conversion with excellent results, learned tons about my van and had a good time doing it. I detailed a lot of it in my blog (link in my signature).
If I was to do it again i would have paid for the engine carrier rather than fab one.
I found that some of the air cooled wiring was a bit of trial and error due to minimal literature out there.
Tom Shiels is an excellent resource as is the yahoo group for the subie/vanagon conversions.
Before you tear that engine out check all the engine codes and try to fix them while in the car, this gives you a good starting point for trouble shooting when you do put it in the VW.
A donor van is helpful too for all the heating components.
Enjoy the process!
Peace
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81 Westy/94 EJ22
www.eastwestyexperiment.blogspot.com |
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ShultzRoadHouse
Samba Member
Joined: March 28, 2011
Posts: 318
Location: Caldwell, ID
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| Posted: Wed Jun 04, 2014 4:09 pm Post subject: |
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The '93 Subuaru does not have any check engine lights on, but you bring up a good point to check codes now while its still in and running. What kind of scanner do I need to purchase? I believe this is an OBDI engine. Great blog, I knew it could be done.
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ShultzRoadHouse
'81 AirCooled Westy RIP
'82 Westy w/ '93 Subaru EJ22
'71 Super Beetle w/ '75 AJ 1600
'12 Jetta |
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sk8architecture
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Joined: September 27, 2012
Posts: 21
Location: South of Bellingham, WA.
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| Posted: Wed Jun 04, 2014 4:13 pm Post subject: |
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Yes I'm sure Mike can help you and they can do the harness for the air cooled it's just not plug and play. You will have some work on your end. Most of the Harness work is just removing all the components not used. I would have to look back at my files but you really only need 4 wires to run the motor with the van. 1. Power through started to alternator, 2. Power to the ECU, 3. Ignition wire to turn on ECU, and wire from ECU to Fuel pump. The rest of the wiring that interfaces to the Van are your gauges which on the air cooled you really don't have. So on mine I ran new wires so I could have oil pressure, tach, and water temp. Used the existing OXS light for my check engine light. Send me a PM and I can try to scan and send you my wiring notes and it should make more sense.
I used the RMW kit and it is awesome. Your trans axle will sit back about 1.25" further back so it will not reach the trans mount. I simply extended the nose brackets on the Trans axle using some angle iron. I can send you pics of that as well. |
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nepawesty
Samba Member
Joined: April 08, 2013
Posts: 108
Location: CO
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| Posted: Wed Jun 04, 2014 5:15 pm Post subject: aircooled to ej |
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| I'm doing it right now. Let me know if I can help. 80 vanagon and ej 25 dohc. Trying to figure out a cooling system now. Radiator is in and I'm working on the plumbing. Expansion tank etc... |
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ScottShelley
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Joined: October 15, 2012
Posts: 596
Location: California
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| Posted: Wed Jun 04, 2014 5:23 pm Post subject: |
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| I did it too with my 82. I had great results. Let me know if you need help or suggestions. |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10371
Location: Sunshine Coast B.C.
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| Posted: Wed Jun 04, 2014 6:18 pm Post subject: Re: Aircooled to EJ22 Conversion |
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At one point I was going to do the exact same swap. During that time, I contacted Tom and he kindly provided relevant info.
He's only a phone call away, and I'm not speaking for him, but I bet he could do the wiring mods required.
One suggestion that may be covered or completely not applicable.
Compare the air cooled ign. coil (15 buss) wire gauge to the OEM wire gauge as used on the Suby. That wire on the Suby may be significantly bigger.
Neil.
| ShultzRoadHouse wrote: |
My question is, can Rocky Mountain Westy modify the harness to work with the aircooled Van or is the modified harness specificly modified for the '83 and later Vans? I hear that a guy named Tom Sheils does excellent harness work but does Tom do custum harness modifications for aircooled Vans? |
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1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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ShultzRoadHouse
Samba Member
Joined: March 28, 2011
Posts: 318
Location: Caldwell, ID
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| Posted: Mon Jun 09, 2014 10:24 pm Post subject: |
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UPDATE#1
I wanted to get more done last weekend but I completly degreased and cleaned the engine & drained/ removed the radiator. Would the suby radiator fit in the Van?
Next on the list is to discharge( any tips?) the A/C, remove the power steering pump and start labeling.
Cheers,
_________________
ShultzRoadHouse
'81 AirCooled Westy RIP
'82 Westy w/ '93 Subaru EJ22
'71 Super Beetle w/ '75 AJ 1600
'12 Jetta |
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nepawesty
Samba Member
Joined: April 08, 2013
Posts: 108
Location: CO
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| Posted: Tue Jun 10, 2014 6:16 am Post subject: |
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| Looking good. My 96 legacy radiator would not fit. Too wide. |
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veloandy
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Joined: December 04, 2010
Posts: 356
Location: Fort Collins, Colorado, USA
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| Posted: Tue Jun 10, 2014 7:56 am Post subject: |
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I did a similar swap and have loved it. I used a lot of different vendors' parts to piece together my swap. I have been SUPER happy with everything I got from RMW.
I have a set of factory wiring diagrams. PM me with your email address if you want me to send you a copy. I did the harness myself -- it wasn't too bad, but I've done wiring before.
All the aircooled wires you'll need go to the double relay in the driver/front corner of the engine bay (Power, On, start, power to fuel pump). Note that the heavy gauge constant power line to the double relay is NOT FUSED from the factory!! I suggest adding an inline fuse.
| Vanagon Nut wrote: |
| Compare the air cooled ign. coil (15 buss) wire gauge to the OEM wire gauge as used on the Suby. That wire on the Suby may be significantly bigger. |
I don't think that's a big deal. The "on" power wire is mostly used to switch the Subaru main relay. The power to the fuel injection mostly comes from the heavy-gauge (10-12ga?) + wire (via the relay).
Other wires that connect to the van (oil light, alternator wiring) are separate from the main engine harness.
New wires from the subaru ECU (check engine light, radiator fan wiring, tach) have to be added from scratch.
I used a junction block like this one with wires going to the ECU on one side and wires to the van on the other to hook everything up. That makes everything easy to see and troubleshoot.
I used a stock Vanagon radiator in front. It needs to be really narrow to fit up between the frame rails.
Badassdubs found with his breadbox build that a Dodge Dakota radiator fits. That could be a good option if you like filling the radiator from the highest point in the cooling system.
| ShultzRoadHouse wrote: |
| Would the suby radiator fit in the Van? |
This van in the classifieds (not mine/never seen in person) looks like it uses the stock Subaru radiator in back:
I considered doing something like this, but went with the stock setup instead. A rear radiator would make the swap a lot less involved. I wonder how well it cools at speed.
Good luck! It's a lot of work, but if you make it to the other side you won't regret it!
Later,
-Andy |
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Vanagon Nut
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Joined: February 08, 2008
Posts: 10371
Location: Sunshine Coast B.C.
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| Posted: Tue Jun 10, 2014 3:03 pm Post subject: |
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Veloandy: cool. I get it. Very different set up.
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1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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brentw
Samba Member
Joined: July 20, 2004
Posts: 18
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| Posted: Tue Jun 10, 2014 4:23 pm Post subject: |
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| ShultzRoadHouse wrote: |
| The '93 Subuaru does not have any check engine lights on, but you bring up a good point to check codes now while its still in and running. What kind of scanner do I need to purchase? I believe this is an OBDI engine. Great blog, I knew it could be done. |
You can read your codes by plugging the green test connectors (located in the donor subaru under the dash just to the right of the steering column) together and reading the blinking lights on your ecu mil light in the dash.
Long intervals between flashes are 10's. Quick flashes are 1's. YOu add up the tens and then add up the 1's to get your code. I have a lookup of codes out on my site at http://www.weidefamily.net/vanagon/
Go to Suby Engine-1 > Wiring > Table Listing of Computer Codes for the Subaru Engines
also have a writeup on resetting codes and reading codes at
Go to Suby Engine-1 > Wiring > Idiots Guide to Subaru EJ ECU Codes
I have a lot of decent information that might be helpful to you on wiring and such. http://www.weidefamily.net/vanagon/Pending_Content/Engine_Conversion/02RemainingWiring/
There are a few diagrams in there that will help you out with your 93 suby.
Give a holler if you have any questions. I co-moderate the yahoo subaruvanagons group with Tom Shiels.
All the best with your project,
Brent
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Brent
1991 VW Multivan Westy
powered by 1999 Subaru EJ25
Portland, Oregon
http://www.weidefamily.net/vanagon/ |
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danfromsyr
Samba Member
Joined: March 01, 2004
Posts: 15144
Location: Syracuse, NY
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| Posted: Tue Jun 10, 2014 10:06 pm Post subject: |
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properly shrouded a OE vanagon radiator will cool a 2.2l subie just fine w/o the lower grill opening cut out.. just make sure it's a new radiator and all ram air goes thru not around and that the fan & T-stat are working fine
I had to open the crossmembers a little to install the plastic radiator lines from the 85+ vans the metal ones from 83-85 fit fine.
you have to run heater lines up front anyways (I ran mine thru the now unused paper duct (but had to remove the damned middle deflector)
I used a rear heater only for a year or so till I had the time to put the front heater in.. since I don't drive it in the winter/snow it was plenty nice to just have heat even from the back. [i]I did use a shopvac hose on a particularly cold day to bring heat to the driver seat..
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| Abscate wrote: |
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ShultzRoadHouse
Samba Member
Joined: March 28, 2011
Posts: 318
Location: Caldwell, ID
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| Posted: Thu Jun 26, 2014 1:06 pm Post subject: |
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UPDATE#2
I ordered the Rocky Mountain Westy 2.2 Kit this morning. This was a tougher decision that I thought it would be. I looked at Smallcar and KEP but I wanted a complete kit so I went with the RMW kit. I still need to purchase a Radiator, stronger starter and a new clutch kit. I found the clutch I wanted at Van-Cafe but will that clutch fit the aircooled? I will post more updates this weekend, I have a lot to do:
Remove the EJ22 from the car
Remove wire harness and ECU
Remove the old 2.0 air cooled( Anyone want to buy a running 2.0 with 8000 miles on a top end rebuild? PM me.)
Busy Weekend but Ill post more pics.
Cheers
_________________
ShultzRoadHouse
'81 AirCooled Westy RIP
'82 Westy w/ '93 Subaru EJ22
'71 Super Beetle w/ '75 AJ 1600
'12 Jetta |
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danfromsyr
Samba Member
Joined: March 01, 2004
Posts: 15144
Location: Syracuse, NY
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| Posted: Thu Jun 26, 2014 1:09 pm Post subject: |
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the aircooled has the same clutch size as the WBX they're all 228mm (except a uniquie european 1.6 aircooled and the 215mm Diesel clutch)
one thing to note is that the trans sits in a more forward position in the air cooled van than the WBX. so the kit may need a little 'adjusting' as everything is shoved forward.. i.e. throttle linkage? intake ducting to T-body.
enjoy the taller gearing of the air cooled trans.. and the few who have forgone Air for heat and power of a conversion.
Dan in Syr
1980 w/1.8T inside.
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| Abscate wrote: |
| These are the reasons we have words like “wanker” |
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ShultzRoadHouse
Samba Member
Joined: March 28, 2011
Posts: 318
Location: Caldwell, ID
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| Posted: Thu Jun 26, 2014 1:26 pm Post subject: |
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When I talked with John @ RMW he said the kit includes a template for making an extension plate for this issue.
That's great news on the clutch because Van-Cafe's prices are the lowest. I forgot to add that I am also going to get a Fuel tank re-seal kit because I get some real freaky looks when I fill it up and I leave a trail of gas! I went ahead and ordered the SS coolant pipes, dropping the tank would allow for an easier install on the pipes I would imagine.
Cheers
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ShultzRoadHouse
'81 AirCooled Westy RIP
'82 Westy w/ '93 Subaru EJ22
'71 Super Beetle w/ '75 AJ 1600
'12 Jetta |
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furrylittleotter
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Joined: May 19, 2008
Posts: 1506
Location: West Seattle
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| Posted: Thu Jun 26, 2014 9:40 pm Post subject: |
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Should be a nice upgrade. Be careful about going to big on tires if, in fact, the air cooled gearing is tall already. The 2.2's additional power can EASILY be negated by gearing too tall. That is my experience. I think you made a good choice with the RMW kit. A gear reduction starter and a coolant system from a donor van are in order. You will need front and rear heater boxes with cores, valves, radiator, relays and fan. I had all this over the last year but have sold it bit by bit. The classifieds here have that stuff all the time. I run a rear radiator but the front stock vanagon is fine as well. I would not put the subaru radiator in the front, just a bad choice. I made my own harness (have done three now) and it was rewarding for me, the best part being i know where every single wire on that ecu and engine goes. I am currently running a 2.5 wrx block with 2.2 heads and custom small diameter primary header. it is very powerful. A stock 93 2.2 will not inspire awe, but is far better than stock and you can always upgrade blocks like I did, using the 93 2.2 heads and ecu later if you want. Make sure you use the square motor mounts, not the round ones and do yourself a favor and cut out the entire firewall, you want that motor as far forward as possible.
I have heard the LUK clutch is not a good choice for that setup so you might want to get the sachs. Do more research on that if you want.
I would replace all wear parts on your shifter while your tank is out if you can.
THe conversion is by no means easy, but it is totally worth it.
PM if you get stuck along the way.
Neil2 |
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ShultzRoadHouse
Samba Member
Joined: March 28, 2011
Posts: 318
Location: Caldwell, ID
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| Posted: Thu Jun 26, 2014 10:21 pm Post subject: |
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I installed new tires last weekend, I went with the BFG All terrain 195 75 R14's, the same size it had on before but these tires just look badass. Thanks for all the info Neil2, Im sure I will be asking for help soon enough 
Cheers
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ShultzRoadHouse
'81 AirCooled Westy RIP
'82 Westy w/ '93 Subaru EJ22
'71 Super Beetle w/ '75 AJ 1600
'12 Jetta |
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ShultzRoadHouse
Samba Member
Joined: March 28, 2011
Posts: 318
Location: Caldwell, ID
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| Posted: Mon Jun 30, 2014 10:55 am Post subject: |
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UPDATE#3
I wrangled the engine out of the donor car this weekend. Took about 6hrs on Saturday to prep the engine for removal, would have been quicker but the hot sun and the cold beers took their toll. Sunday we hooked up the chains and got her free in about an hour with some fierce wiggling.
Next weekend Ill be removing the harness and ECU & pulling the Vanagon engine.
Cheers
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ShultzRoadHouse
'81 AirCooled Westy RIP
'82 Westy w/ '93 Subaru EJ22
'71 Super Beetle w/ '75 AJ 1600
'12 Jetta |
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iliketowalk
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Joined: April 29, 2011
Posts: 614
Location: Northern CA
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| Posted: Mon Jun 30, 2014 2:01 pm Post subject: |
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In for updates... Just finished installing the RMW kit, pretty happy with it so far. The manual was lacking in a few areas, but pretty sure they've updated since I purchased the kit.
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1986 Weekender "Birch" |
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