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Fri May 02, 2008 5:39 pm

Day 2 progress report...
Started working on the van about 12:30pm.
Finished about 6.

Step 1: Coffee

Step 2: Success!

Step 3: Beer.

I don't know where the day went. I started the day ready to drop the motor. Seemed like I worked until 3:00 still thinking I was about ready to drop it. Picked son up from school and then dropped the engine after that. I was going to do it myself, but luckily my friend John came over to lend a hand. We used one jack on the tranny end and the other under the engine at about the point the exhaust crosses from one bank to the other. Dropped down with only minor issues - a vac line and a coolant line that I had missed. Note that I waited until the engine was partially lowered to remove the electrical connections from the starter - was a lot easier that way.

Fri May 02, 2008 6:50 pm

for what it's worth, here is my build thread.
http://www.thesamba.com/vw/forum/viewtopic.php?t=198281

I'm not much of a "documenter" and some of the picture links are broken, but let me know if if can be of any help.

Fri May 02, 2008 10:19 pm

Rs-4 - thanks for the link. Hadn't seen your write up. I had the same issue with the clutch cylinder and the tranny bolts. I'll be sure to print out that whole thread.

Sun May 04, 2008 7:56 pm

Day 3 Progress
Soccer and watching friends at the Chalk Creek Stampede bike rice got in the way today. All I did was separate the trans and engine. Four bolts, 1 of which is the long allen that is common to the starter. Cleaned up the trans a bit. Not sure if I want to paint it.

Sun May 04, 2008 8:11 pm

Day 4 Progress
Worked for about 5-6 hours removing rear seat, pulling old harness and cleaning engine compartment. Springtime in the Rockies brings friends and neighbors out of the woodwork - so lots of chatting with folks today ... so probably only worked a solid 3-4 hours.

I followed instructions in Bently section 77.2 to remove the rear seat. My added complication was the need to remove the Propex heater mounted there as well. Was annoying as I had just redone my copper lines to that a few months ago and had to cut one of them. Otherwise the seat came right out.

Followed advice on removing the VW harness provided by Tim King and Warren Chapman via Brent Weide's site (www.weidefamily.net/vanagon). Fairly painless, just time consuming. seems like I'm pulling a lot more original wire (the VW harness) than will be going back in (Subaru harness modified by Tom Shiels).

Spent most of the time cleaning. As Chester mentioned, there is a ton of tar, cosmoline, etc in there. Especially in the rear valence. Think I did a pretty good job. I'm not going to paint the engine compartment. I'll just touch up a few of the brackets.

Tomorrow I plan to install Tom's harness...

Mon May 05, 2008 8:30 pm

Day 5 progress.
Worked about 4 hours today. Feeling like I'm on track. Let's install the harness today...

The Subaru harness as prepared by Tom Shiels (http://www.subaruvanagon.com/)

The detail on the Shiels harness is perfect for a parts monkey like me. Every wire has a nice label on it. He also provides a packet of papers to translate between the Subaru and VW wiring diagrams

Now, to stuff that large harness into a small hole. My original rubber grommet was damaged, so Tom provided this oval one.

The hole was a little difficult to cut - the Syncro fuel tank(plastic) is located just behind the area that needs to be cut. I used a saber saw, sawzall, and round metal file. Stuck a piece of sheet steel between the insulation and fuel tank for protection while I drilled and cut. Painted the edges with touch up paint.

Now it should fit. Feed the wires in from the passenger compartment side.

through to the wheelwell....

to the engine compartment.

And here is what the harness looks like installed under the seat.

I decided that I'll add some sound control stuff while I have the seat out. Ordered a roll of RAAMmat BXT last night, so I'll hold off to reinstall the seat.

Day 6 plan: Clean and paint engine mount, paint coolant tank mount, install Kennedy adapter plate and flywheel.

Mon May 05, 2008 9:18 pm

Hey Dude,

So far so good but I was at least hoping for a small crack of (_._) by now. Remember, you promised... :oops:

- Chester

Tue May 06, 2008 6:37 pm

6 days in, and I think we got a stalker! :shock:

Tue May 06, 2008 8:32 pm

hmm...a stalker....this could get interesting.

Tue May 06, 2008 8:48 pm

Day 6 Progress
Was only able to work on the van for about 3 hours today. What I did do wasn't too exciting.

The dust shields were covered with tar and a bit of oil. Nothing that elbow grease, Simple Green and steel wool couldn't cure.

Also cleaned, primered and painted the engine cradle. I happened to have a bunch of Eastwood products around from restoring my Ranchero. Otherwise I would have just used Krylon. Used the clear for the dust shields. 3 out of 4 new Corroles cans were duds. Guess 5 years on the shelf will do that.

Now, if the paint is cured on the cradle, I'll mount it and the Kennedy adapter and flywheel to the engine tomorrow. Otherwise, I'll do the new stainless coolant pipes and radiator.

Tue May 06, 2008 8:57 pm

ranchero wrote: Day 3 Progress
Soccer and watching friends at the Chalk Creek Stampede bike rice got in the way today. All I did was separate the trans and engine. Four bolts, 1 of which is the long allen that is common to the starter. Cleaned up the trans a bit. Not sure if I want to paint it.

You should:
http://www.benplace.com/mike_syncro/mike107.jpg
http://www.benplace.com/87_syncro1.htm

He he he...

I'm watching your progress... i'm curious about DIYS folks. Even if i already did over 15 conversion (and 12 to come) i still have great respect for people who try themself.... and hey, i may get Hans from Vanaru to read that thread... I'm doing an 05 this week also, an 07 the other week (you guys don't want to mess with 05-07 engine for now...) and an SVX with Hans. If you are in real trouble... i will pitch in.

Best luck, Ben
http://www.benplace.com/

Tue May 06, 2008 8:57 pm

Great progress! Now if you can just resist the urge to "do these little things while the engine is out..." you should finish on schedule! :)

(at least this is what turns my 2-day engine pulls into multi-week extravaganzas!)

Wed May 07, 2008 10:27 pm

Day 7 Progress....
Well, the install began one week ago. I'm pleased with progress so far. Here is what I did today. Worked about 4 hours.

First, let me start with a question. My engine is from a 2001 Forester. Unlike my outback, the power steering fluid reservoir IS NOT mounted on top of the PS pump. Instead, it mounts to a fender. For those of you who have this version, where did you put the reservoir? I'm thinking that since I'm relocating the coolant expansion tank to the pass side, that I can put this reservoir where the expansion tank used to be. What say ye?

OK, on to progress. I said I was going to start this swap with the engine fully prepped, but I haven't quite finished that yet. Today I installed adapters for the oil pressure and oil temperature senders and then the senders themselves. Left the stock idiot light sender there. I'm not planning on doing an oil temperature gauge just yet, but wanted to install the sender while I had the coolant and intake manifolds off. Got this stuff from egauges.com

OK, on to the Kennedy adapter plate. I had to file my alignment dowels down a bit, and move the holes for the included dust plate, but otherwise install was straightforward.

I love smooth round things. The Kennedy flywheel is a work of art.

Clutch disc and alignment dowel

Pressure plate installed. One surprise was that the clutch kit didn't come with bolts for the pressure plate, so I had to take them off the wasserboxer. I was slightly disappointed with that because I wanted to leave have a complete 2.1 engine on hand in case another vanagon comes along. Oh well no biggie.

Installed Tom Shiels' coolant bypass adapter. I originally thought I would go with the standard Mastercraft/Hatfield/Smallcar cooling system scheme, but after reading a bit more about the function of the system in cold weather (I live at 7000 ft in central CO), thought I had better bite the bullet and get this.

OK, the engine is ready to bolt up. On to the trans. I bought a new clutch release shaft and bushings. Spent about an hour and a half trying to get the lever off the shaft. Kroil, torch, light taps with the hammer...no go. Started contemplating the need for a plasma cutter. Came up with a rationalization for the wife. Looked again at the price of plasma cutters. Went to the basement and got the wife's Sawzall (yes, seriously, it is hers). Cut through the shaft in about 1 minute. These are the important posessions in life: bailing wire, duct tape, pinto beans, coffee, and now, sawzalls.

Day 8 plan: install clutch shaft and bushings. Install new shift rod bushings. I probably ought to work for pay for awhile. And if there's time, I'll mate the trans and engine and try to get them into their new home.

Thu May 08, 2008 6:31 pm

wow! brief nudity, now mating to come... this is just like a national geo. special! :roll:

Thu May 08, 2008 7:01 pm

Go Man Go! Great progress. Is that the Small Car mount? I'm thinking of trying one on a baywindow conversion, with a modified mustache bar.

Thu May 08, 2008 7:35 pm

George that is the Small Car mount...I'll make a post with a detailed parts list and costs soon

Thu May 08, 2008 7:52 pm

Day 8 Progress...
Worked about 3.5 hours today.

Got the new clutch release shaft, bushings, and throwout bearing installed in the bellhousing. Installed new shift lever (the thing with the ball on the side of the trans) and bushings. Then my wife helped with some mating between the transmission and EJ25. She's good at that kind of stuff.

There are three studs in the Kennedy adapter, you slide the trans onto those and then direct the trans input shaft into the pilot bearing. Went in very easily. The fourth attachment is the starter bolt. Mine is a long allen head bolt. I had to grind the circumference of the head of the bolt down a bit to be able to get a straight shot into the starter and then on into the trans and adapter plate and be able to turn the bolt. Otherwise things bolted up smoothly.

So I decided not to paint the transmission. it looks great for those of you who have done it (Ben !) but it has been windy here and I didn't want to do a crappy job. Next time it is out I'll do it. Besides, I hope to have it really dirty again in a few weeks! And I'll get it dirty many of the weekends this summer.

Note the bumper sticker - the irony does not escape me. Other than some Permatex sealants and miscellaneous bolts, nothing on this van was purchased in Chaffee County.

Tomorrow I should be able to bolt the trans and engine in.

Thu May 08, 2008 8:18 pm

Quote: First, let me start with a question. My engine is from a 2001 Forester. Unlike my outback, the power steering fluid reservoir IS NOT mounted on top of the PS pump. Instead, it mounts to a fender. For those of you who have this version, where did you put the reservoir? I'm thinking that since I'm relocating the coolant expansion tank to the pass side, that I can put this reservoir where the expansion tank used to be. What say ye?

Free Hint :-)

Why not use the existing VW reservoir?
http://www.benplace.com/yvan/subi_yvan2.jpg
http://www.benplace.com/yvan/subi_yvan4.jpg

Very easy if you have the Forester PS hose.
Use the hi pressure one with an adapter to the Vans line!!!

Just buy a low pressure hose from the PS pump to the VW tank!!!

I'm telling to much :-)

Ben

Fri May 09, 2008 5:19 am

Ben - Thanks!!! That should have been an obvious one to me, but wasn't. I was looking at some of the Subaru install pics on your website. I like how you trimmed the passenger side dust shield to clear the large coolant hose - very trick. Did you have to do anything special to the rear dust shield to make it work since the crossbar Subaru engine now sits about 2-1/2 inches further back? It looks like some people just cut the bottom of the shield off, but I see it in a few of your pics.

Fri May 09, 2008 8:05 am

Before you put the engine in, could you take top, left, right, back photos so we can get an overall idea of how the mounts go together?

Thanks, George