TheSamba.com :: View topic - Hawaiian Westfalia Vanagon,Subaru EJ22+UN1 transaxle

Thu May 27, 2010 7:32 pm

Hello!

Here is my van when I bought it in September 2008,coming to O'ahu with my suitcase and 2 surfboards, I bought it 36 hours after my arrival from France (I still have over there a 1989 Hannover Edition,1.9TDi-M,5 speeds,Devon pop top roof etc...)

That's the home in where I still lives today,and my daily driver.
I did since I have it 20 000 miles,I can't believe it's so reliable :lol:
I never had such reliability on my stock diesels 1600CC and 1900CC in France,until I switched to 1.9 TDI-M before coming to Hawai'i.

here is the video of the TDI engine

Price:4600 USD
Year:1987
mileage:++ 175 000 miles,le compteur est a reparer,il a lache il y a peu de temps...je vois les numeros de traviole Yellow_Flash_Colorz_PDT_13
Engine:2.1L MV
Tranny :4 speeds ACW
options:power steering,AC,electric mirrors,power locks,power windows,bad paint with Ford color,some issues (easy to fix)

The french Vanagon magazine

The french vanagon forum

mmmm,Hawaiian rust ,and the VW are not the worst ones!!
ding
1/3-2/3 sliding window for Westfalias.

Missing washer ring

bad repair!!

Missing key....
rear wheel:modified studs,missing cone on rim.
cheap work:welded nuts
,shiny new tires with spray paint job:so funny:what are trying to hide?I'm an expert!! :roll:

bad rack and pinion boots
fucked up thread on shocks Yellow_Flash_Colorz_PDT_10

accidented side:door closes badly.

different key on drivers side,dented door:door has been replaced,inside poorly repainted

penetrating rust,missing vinyl inside
fucked up bushing,totally missing:impossible to find 1ST and 2ND gear:but I knew why.....talked the price down 900$ :twisted:

VIN number
we have numbers here in Europe
so poorly done....
swivel seats,battery battlefield....

some tags

different headlights also from Europe

bad!

El Motor,benziner,ach!!!!

muffler made in USA

2nd floor bed
god damn AC,I want some space :roll:
for a living
and it works!
US fridge

That's for now,I'll put what I've done to it later.

Cheers 8)

Mon May 31, 2010 2:31 pm

the day I got it,it was impossible to shift into 1st and 2nd gears,so I parked on the cell phone waiting area for the airport and managed to fix it up with the few tools the owner gave to me,and a roll of ducktape.I couldn't find the bushing part locally...
I extracted the pin with a chinese chopstick,made with very hard wood that I carved the right diameter with a knife.
Put the front bushing to the rear (missing) on the tranny selector,and made one for the front out of ducktape and greased it with oil from motor leaks :lol:
It stayed like that 6 months,it was shifting so nice,that I was lazy to work again on it to put the new bushing that I received from my friend Tito,who came for 3 months visiting me,living in the van.
I paid half his plane ticket so he can bring my dog from France,and some spare parts.
I received soon after by mail,some big spare parts,cheaper than in the USA,with my so beloved tool box,with quality metric tools,all I need to fix anything on the van.

I fixed up the front shock absorber,the threads were far gone,so I put a U clamp to fix it temporarily.

I then met a guy pretty quick,how became my friend:he's renting vans ,Oahucampingvans.com

I worked a little bit for him as a mechanic,and he gave me the 2 missing tables for my van,one of them taken in this bad 2.0L aircooled Vanagon from 1980,with AC :shock:
I got some spare parts also from it,like little caps for screws etc...

Then I replaced quickly all the gas lines to not have a fire in my home,took off that shitty part,useless,went straight,one shot gas line.
brand new gas lines 8)

Then I noticed my parking brake was weaker,I tried to fix it,but right side cable was rusty as f...k!!!

so bad,I didn't put it back,and went to Jamie's place to get another used one,that was like 10mm to short,but I put it anyway,night was coming,grrrrr

I didn't have a jack stand,so I went in the river mouth of wailupe river,where I was,to bring back this super heavy concrete bloc,50yards:that was a pain in the ass!!

Then I worked on the fridge,didn't work as nice as it should be...

Yellow_Flash_Colorz_PDT_13

I greased the air dose pump,the little tiny check valve was stuck also,I fixed it too.

Another problem came soo after:the little coolant vase broke down:too old,cracky

Again,my friend Jamie lent me one,while a new one was coming anyway from England with the canvas tent.

I bent back the bumper so I could check the fluid levels.

Then Murphy's law:my flip flop broke down :lol:

Like new son!! :?
One day,I lost the window into the door?? WTF!!!

Fixed it with a piece of copper wire,zip tie wasn't good.

under the bridge,to work out from the rain

Mon May 31, 2010 2:55 pm

Of course,first day I filled the tank,after cleaning it,I broke the drain cap...too old....

Some epoxy putty,and it's like new.I signed the artwork.

Signature
Maybe this was a CD charger?

I did also some archaeology,and tunedup the swivel seats.
You can also see the early model table foot,screwed without drilling:hammer and big screws to go through the metal....the 2nd generation didn't have the holes on the same spot...

Cleaning
Mo' betta

A little bit of love lub.
Factory error :o
Battery tray is bad...very bad!!

:mrgreen:

Tune up for bad working faucet also

I'm waiting for curtain hooks from France...

I cleaned the old glue for the skylight screen!
Profesionnal!!
I couldn't find a non AC sun screen....
little trick to make it work anyway.

Put back the shelf where it belongs,with new dowels
Then ,DA big issue:we filled up the propane tank,leaking badly.....I had to wait an hour so it can be empty and I could drive:the shop was mad at me.....oops :oops:
No ice in paradise :lol: Hawaii
I removed copper lines to empty it faster.
The end is coming...almost empty!

I replaced the o'ring,but leaked soon after again:not the same stuff asrwater....and nobody wanted to sell me a real industrial propane o'ring

I front of the store,fixing....
dimensions

Filling side

I finally received my tools from France and canvas tent from England.
This was missing,very important piece of rubber
"Hey,Luna,what would you think if Obama's elected?"
"Like you,I don't give a shit:gimme a treat instead!!!"

The longskate tool to maintain the roof opened:I've unbolted one arm at a time to put on the canvas.
The model after 1984 is better:using screws and not stapples 8)
plumber's putty to help sealing

The spoon tool!!

Mon May 31, 2010 3:09 pm

Odometer was not working,and I needed it to work for safety check....??Numbers were crooked,so I knew that the axle pin went out:easy fix.
I finally found a safety check,and was easy:so funny,it was raining,so he came out fast,checked lights and wipers,asked if it was braking good:I got it,incredible!!!!They don't check ball joints and shit??Brakes and wheel ripping on a plate?etc....This is a JOKE!!!!

lthe magic tool
I fix also the contacts in here,with aluminum tape:like new!

I tried to glue the pin with some neoprene glue so it was not definitive,it worked one mile :lol:

Yes,I still love you,even fucked up!!
There's a little offset for one number,but fuck it,it works,I'm fed up!!

the tool to remove the speed neddle,for greasing the gears

It didn't work long.... :evil: I used a paper clip to retain the pin,but didn't work:it doesn't spin?? Eureka!!! I finally figured it out:the pin has to be stuck in the aluminum gear!!
The aluminum gear is not in plastic because it spins more in a lifetime than the others :idea:

How to glue the pins without glueing the numbers???hmmmm

Protection with aluminum tape prior to glueing.

It's still working fine,after 20 000 miles!!

The bad joke when I received the louvered grill!It doesn't fit Westfalia sliding windows ,that are 1/2-2/3,instead of 1/2-1/2 :evil:
I bought a pair of correct ones so I can fit these louvered grills for my dog and I, I never removed them since I got them.
Differences

Big work,that's why it rains inside??!! :lol:

bad corner

I want a window like this one!!! My friend Tito
Cheap fixing for now.Fiberglass and grease

Mon May 31, 2010 3:33 pm

Some nice pics of the moment,2008.

Rock piles,North Shore Oahu

Mokuleia Beach Park, North Shore Oahu Decoration by my artist friend Tito

Chun's Reef, North Shore Oahu:2 fishes ,1 shot:I almost drown myself to bring these back to the shore,shaking out of the water....The previous dive,I caught a Umo Umo and a nice Casio watch,lost by a surfer!! I lost it surfing exactly the same spot a year later...Maktoub!!

Wailupe Beach Park,near de Honolulu

Treasures from the Sea

Sunset Beach
The end of my Axel Lorentz surfboard.....
I snapped it,then finished it :a video of it:

Foodland, Sunset-Pupukea,

Alii Beach Park, Haleiwa, North Shore Oahu:

Sunset Beach-Backyards, North Shore Oahu: lazy Hawaiian monkseal

I was recovering from an infection at the leg,watching a movie while my friend Tito was surfing at Off the Wall A cow went to disturb me,dog was growling:oh,WTF!!!!I scared the cow,that ran away on this picture...too late!!
I went back to my movie,and what's that ???Yeah,whales!!!!!

The night at Rock piles.
Luna is chasing ferral cats,on the coconut trees!! High!

Mon May 31, 2010 3:41 pm

Christmas 2008 on the beach near Off The Wall in the van!!

Soon after,some stupids people called a cop to stop the bonfire....he was nice at least.Freedom.....

A french wine for american people,so funny translation :lol:
My christmas gift,waiting for the new custom license plate
Time for dinner!!!

Yummy, chicken thies,fried, fried potatoes,Curry chicken,salmon and rice sushi and a pumpkin pie

Christmas morning on the beach
hungry Jack...russell :lol:

Mon May 31, 2010 4:06 pm

I fixed the door panel that was falling apart....
screws are longer now,from VW
custom plastic film

black cothes hanger instead of the whites ones I got earlier.

Rear back brakes were leaking,mostly the left side The bearing was so fucked up,that the drum was grinding the backing plate,so I put some washers waiting for the parts to come from Germany.
Right side,like new son!!

I replaced on the beach park the rear left bearing ,not easy with sandy winds...and a bearing coming stuck on the stub axle....
The left side had a lot of play,the silly mechanic reused the old circlip :roll: ,that didn't stay in the hub,so my wheel was moving almost 2 inches in and out!!!
Too easy to pull out....bearing now is stuck on the driveshaft/stub axle

quality has decreased at VW...old and new
I removed the spacer,but fuckedit up too,and it's tempered steel:filing it was very long!!!

Inner bearing right rear:fu...g local mechanics,they didn't put grease between them!!!

Febi Germany on left and Fag Korea on right
Riveted one side on Korean model,riveted both sides on German one.
Febi Germany on left and SKF Usa on right:rivet is similar,just the shape of the head is different

Korean bearing contact flat surface is smaller

I put the German one on the right,left was Korean inner...and brasilian outer(or south amercia somewhere,I don't remember):3 months later,I had to replace to outer one,innerone is kept as a back up,but replaced it too....

I was almost loosing that piece,so I fixed it with fiberglass,but it moved before drying.... :cry:

I bought some original floor mats,mines were missing,replaced by shitty stuff
It took me a week to find a car wash willing to clean them,there is only one that is coin operatedon the island,I had a hard time to find it....They were smelling cat pee!!

Dusty shit!

crappy drywall screws,what a job!!!

where it has been accidented

wouah,luxuous!!!!

I never seen these options before....so I took them!!

I had a bad coolant leak on the freeway...
I had to fill with water,run uphill then downhill,stop again to bleed the air etc...AC is empty,so I turned the AC ON to make the radiator fan spining.

Lucky:part was in stock at Hawai'i import parts.
Guilty piece of shit!!

brand new!!

water pump replacement,was making bad noises
I hate VW wasserboxer engines,what a mess on the coolant circuit:so many junctions that can leak,hard to reach also:I want my diesel!!!! :twisted:
New water pump

sanding
good job:starting at 183125 miles

OXS replacement didn't change anything....still runs funny at low RPM

The distributor had dengling wires:let's put them back!! :lol:
I turn the key on the ignition,it almost started....then nothing???Argh!!!!wires are cut short inside!! And I'm in the middle of nowhere,no cellphone reception.

I skated until getting reception to call a friend so she can lend me her car,went back on the other side of the island picking up the part at my friend Jamie's ,back to fix it.I did it by night,with a bicycle LED lamp in my mouth,eye balling.I started on the last piece of juice from the batterie.

Mon May 31, 2010 4:09 pm

I backed up in a plumeria branch,making like an elbow :evil:

tinting is strong!!!

the new applicant

new glass from another rusty hatch
Not perfect,but good enough for sleeping tight!

Mon May 31, 2010 4:12 pm

this is not connected??
old injector seals

new seals

cleaned injectors

cleaned contacts in distributor [/url]

intake seals new

I replaced twice the oil pressure sensor,the first new one was not the right model...

Mon May 31, 2010 4:17 pm

there was some play...new VW parts in stock,I like it!!

Selector shaft seal replacement

part number.(there are 3 different models depending of your tranny)

guilty leaking seal

I only had a broken flat screwdriver to push on it.
Done

some covers have an o'ring here

nice!!

Mon May 31, 2010 4:24 pm

I had a hard time opening the trunk.... not correct angle

I removed the useless heater

Happy to remove everything to clean out!!! :shock:

And I even found an old french coin,10 Francs,from 1989,with some other US coins in a sealed bag.
Who wants some sand? So fun without a vaccum cleaner... :cry:

shiny MF
straight!
left side

Silicone grease on threads
I wish I had a piece of wood and jig saw to redo the bottom.

Little maintenance on sliding door

I took time to recombine the driver's side lock,I found some pins from old door handles.

My beloved drunk and on ice micronesians accross my girlfriend's studio had fun the other night.I never spearfished a micronesian,I'm considering it now.

WTF?Ho bra,you too weak,didn't go thru window:try next!
But didn't work either,was opened with louver grill,so double glass....!!! Ho,brah,try mo' betta on da front one

I took them2 shot to do it,first shot in the aluminum trim
It went on steering wheel then on ground.

60$ tinting before mounting,40$ for the glass at Jamie's.At least the rear left window is tinted now,behind the cabinet.
A few hours later,I was parked at the same spot,giving these people the angriest look ever.Nobody has seen anything,but they spent their days doing nothing sit on the stairs or the balconies.
Cops were useless of course.Not the first time it happened:only one guy as never been in jail in these condo units they said.
Gimme some plastic,I can solve the problem for cheap :fist:
2 hours of cleaning fo rmy girlfriend.

I've put some old school AMG rims last year.16"

lI've put some rubber floor mats from France,I could find some here...so much better than the carpet model,easy to clean dog hair and sand!!!More ugly though...

Mon May 31, 2010 4:27 pm

Here we are:The Subaru stuff:

Subaru Legacy 1992, 500 $,109000 miles

I bought it no papers,was tagged abandonned etc...but runnig super fine,super clean coolant circuit,clean engine,clean interior:awesome grandma' car
My girlfriend drove it to Jamie's place.

2.2L

Cleaner,right?

This will be modified.

Where is the computer???Hard to find!!!
I take the instrument cluster just in case,I never read about Subaru conversions...
Here it is!!!Computer!!>>>SAD,that's ABS brain..... :oops:
Fuck it,I break everything to take out wiring harness,faster!

4 1/2 hours to do the job,pretty quick!!And I also too the time to remove a side mirror to sell 20$,nobody wanted parts on craigslist,I gave it for free to a guy who picked it up fro scrap metal,AT was good!!!What a shame....

Mon May 31, 2010 4:38 pm

I took all the wiring harness since I didn't have time to document myself about wiring harness...
5 hours later,I cleaned it a little bit,stuff that I was judging useless because not connected to engine.

Engine was just hold by one last bolt

Victory!!

Empty,nothing for me in here

109000 miles and it's clean :shock:
scary timing belt!!!

Last kiss before goodbye

Left:starter for MT on ebay,right for AT

Mon May 31, 2010 4:40 pm

* 93 - 96 SUBARU IMPREZA 1.8L SOHC
* 90 - 01 SUBARU LEGACY 2.2L SOHC
* 95 - 01 SUBARU IMPREZA 2.2L SOHC
* 91 - 94 SUBARU LEGACY TURBO 2.2L SOHC
* 96 - 99 SUBARU LEGACY 2.5L DOHC
* 98 SUBARU IMPREZA 2.5L DOHC
* 98 SUBARU FORESTER 2.5L DOHC
* 99 - 01 SUBARU FORESTER 2.5L SOHC
* 00 - 06 SUBARU LEGACY 2.5L SOHC
* 99 - 05 SUBARU IMPREZA 2.5L SOHC
* 00 - 06 SUBARU OUTBACK 2.5L SOHC
* 03 - 06 SUBARU BAJA 2.5L SOHC

list of the Subaru oil pumps that are the same as mine.

Mon May 31, 2010 5:05 pm

I hate when it's not reliable,so I did some replacement:

New timing belt kit
New clutch kit
Engine cleaning
I aligned pulleys before opening,since I don't know anything about Subaru....was useless :wink:
R for RIGHT SUBARU side
This arrow has to be aligned for timing
Pulleys all aligned

Crankshaft
You can switch sides of cylinder heads,but I didn't want to.
Information for bearings I think
14MM 12 points for removing head's bolts
I marked the bolt to reuse them on the same spot
Timing belt tensioner is like a piston that pushes.
12mm X 2 units
without tensioner
now you can remove timing belt
Timing belt goes one way only

view on "R" side,plug is an allen 14mm
"R" side:impact gun to remove pulley bolt
only pin is utilised,not the groove
timing belt covers removal,bolt stays on to not loose it.
From 6 to 1 removal,leave number one loose on it.
Knock it with a mallet,number one bolt is keeping the head from falling down on the ground.
Cylinder head "R"
Head gasket
"R" pistons:like new :shock:
"R" cylinders:you can still see the honing after 109 000 miles!!!
solid water pump!!will be replaced just in case
10mm head bolts
Aquastat with pipe
Water pump
Now you can see the "L" side plug for accessing the piston wrist, front part of engine
Remove this part
Now I can see better
A real allen 14mm will work better of course :lol:

Piston wrist circlip
Some paper towel to prevent falling from the circlip,we never know
Smile little clip !!
How to save a tool at 330$?? Buy a 3/8 concrete anchor :wink:
Concrete anchor,coupling,threaded rod:5$
Hammer extractor then.

Subaru tool at 330$
You can use this GM/Ford tool also ,but mine is the best,it's cheap and easy.
I push the piston out with a bent thread rod,as soon as the first ring is out,pull it with your hand.
idem
Piston is like new!!!
I marked the pistons "R" and "L" ,arrow points toward timing belt.
All pistons with their wrists pins.
wrapping for protection

the 34$ ebay water pump,no way in hell I'm gonna install that piece of shit!!so disappointed.....
So bad inside and propeller .The subaru gasket is metallic,this one is paper.
Subaru outlet to aquastat
Water pump "OAW":different impaler,smaller outlet??
I bought a Cardone water pump on the left, Subaru model is on the right:No play,good quality,87$.
Cardone on left,Subaru on right
Manual transmission used flywheel.

Mon May 31, 2010 5:07 pm

the small car kit.

Mon May 31, 2010 5:20 pm

I replaced tranny so I could work on mine to put longer pinions,my friend Jamie is lending me one for now.

I finally changed my mine,it was too expensive to upgrade the VW tranny and still have a piece of shit.

For less than that,I bought a UN1 tranny from France,my friend sent it to me through the mail in a puzzle mode :lol:

I rebuilt the VW tranny with all bearings new,new seals and synchro rings,bearing etc...and sold it.

Wiring instructions for 1996 EJ22 Subaru

Mon May 31, 2010 6:03 pm

3 parts for this ring,the oil one.The top one as a little thingy,important!
same,the middle one,new
the old one
cleaning
cleaning using the old top ring
clean enough
ring number 2:letters on top
ring number one:letters on topalso
cheap tool is good enough
the oil ring in place
head cylinder work
head cylinder cover
you can leave the M6 bolt in place to keep everything together
homemade tool for compressing valve springs
Cheap!!
cylinder head with camshaft
don't mix valves and springs
camshaft pulley sensor

naked!
tap out with a pvc tube the seal cap.
my thumb was soare after a while,so I used a correct size piece of tube o put the valve seals
All the family back together
New seals and gasket for the cover
cover removal to replace gasket/seal
head cover seal/gasket
cleaning
pistons back in engine
factory little piece of aluminum,bad....filed away.
cheap tool
Another factory piece of aluminum,never went away :P
I put upside down the engine to have the connecting rod facing the hole.
pray that the connecting rod doesn't move
new circlip back,180° turned to be sure it's in the groove correctly.
New o'ring here also
Red Loctite on bolts
3 on 4 were easy,this one took me 20 minutes!!!!
new aluminum flat washers
Head gasket set with Fuji stamp(Subaru),and cheaper than Subaru dealer:yesssss!!!!!
Subaru son!!!
Voilà!!!
I didn't have time to replace this one
new o'ring here also
seal removal on oil pump side
better new one in Vitton
input shaft bearing,the new part number is on the box,compatible for VW input shaft.
tap out
Old subaru in black and new VW compatible one,in red:bigger.

Longer MT bolts for flywheel
Blocking the flywheel
Fuck,the new Subaru disc is 22 splines but bigger than VW 22 splines...I wanted to stay all Subaru for the clutch.I could have used Richard Jones special input shaft http://www.rjes.com/html/clutch_components.html , http://rjes.com/html/subaru_input_shafts.html but he didn't want to sell it to me,since SC has stolen his bellhousing design.....He has better products mostly,but they didn't come easily on google,when I did some research...
Old disc Subaru/Exedy
new disc Subaru/Exedy
22 splines Subaru....

Mon May 31, 2010 6:18 pm

I have to determine how much the input shaft has to stick out from the bellhousing.....I've asked SC,it took them forever to answer that question :cry:

Finally,the new oil pan!!

shortened oil sump

I tried to reuse this bracket but I gave up.
long is Subaru original part
Anaerobic sealant
beautiful
Nice,the engine stands up itself
They resist 9.5 tons pressure,but not compatible if you reuse the subaru silentblocs
the aquastat with pin
pin towards belt
cleaning the elbow pipe
Timing belt covers with new seals when furnished
a little bit diappointed on this kit,less thick ball bearing...
front view
do not forget to put the bracket for the tensionner pulley,otherwise hard to find the spot,hahaha!!!
tiny grease on the axle
Camshaft pulley with sensor on sensored head cylinder
lock the belt,align marks
compress tensionner and lock it with small allen wrench
push to the right,don't lock
all marks to align
start from left while installing pulleys
push to the left,lock,release:timing belt is done.

Covers to be done
Luna,the foreman to inspect the job (it's also meaning foreman in Hawaiian,funny):"where's my treat?"
Voilà!!!
This one was too long,I don't know why,I had to cut it.

Wiring instructions Legacy 1992,there is a little mistake on the name of one or 2 plug/wire,but easy enough to understand ,the wire number is correct

Mon May 31, 2010 6:23 pm

I hate electricity works on cars.....but I have to do it anyway!!

It's not difficultin fact,and all that I stripped out from the wiring harness without instructions was correct,I just cut the diagnostic plugs..... I extend the wires,didn't give a shit about colors,too many,too many spools to buy!!
VW stamped,hahaha!
clearer!!!!finally!
soldering

I simplified these stupid kind of detours
I want the ECU where it belongs
An old velcro watch wrist band works nicely for holding the main relay!Bolted on.
The pump relay is held with a plastic strap.
The flat thing is hold by one screw,on one of the VW spot.
It gets better!!
Not too bad for a first job...