2.5 SOHC Conversion Journal

[powderedwaters]

NICE....engine swap, dog, girl, mexican blanket....your set!
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89 VanagonGL Hannover Edition 2.1 AT

[ZimZam]

Congrats Kelso. Nice work. Thanks for taking the time to post all those pics. Sweet. I'm so tired of driving mountain passes in 2nd or 3rd gear.
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'85 Cabriolet (Margo)
'87 Westy (Heidi)
'75 Porsche 911S Targa

"Nobody trusts anyone, or why did they put tilt on a pinball machine.”
- Steve McQueen
"It's just metal, when rusted and dented , anything you will do will be better. Stop being afraid. What they (VW) did many year ago is not better then what you will do now." -Ben

[vwkelso]

Little update, I've put over 1k miles on since finished. Not one single problem, bleeding was very easy, I just used my vac. bleeder and it was done. This past weekend we took it for its first "real" road trip up to Steamboat Springs. Crossing over 2 mountain passes on the way. It's everything I wanted and then some, SVX would still be nice, maybe next time

Most of those pictures are from the first pass, the 2nd really iced her up badly. TONS of ice on the under side of the van (pretty much a solid block lol), and this reminds me when I installed my new throttle cable the link between the metal tube and the new cable has rubber hose as a connector to guard the open throttle cable. Mine was rotted away and not really worth a crap so I replaced with new piece of hose when replacing the cable. Everyone knows to replace there fuel lines and check brake lines but this should also be on the things to check/replace asap. Water can get into the cable and corrode it or even worse freeze! Been there done that I guarantee if that wasn't replaced my throttle would have frozen driving over those passes. Just something to be aware of.
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[vwkelso]

Well what a great day it was, got cooling system done, exhaust, intake tube, heat shield, throttle cable etc... it's all done. She runs like a raped ape, I couldn't be more pleased with how everything went!! Have some odds and ends I need to finish up and some organizing but it's pretty much a rap. I'll take some pictures in a couple days when I get the time. This thing will just fly up hills now it's AWESOME~!!! I can't stop smiling
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[vwkelso]

Ben I really like your idea of the ECM in the RR. I did a test fit of it over in that area and it seams like a really nice fit. I need to do some hunting around and find a nice container for it all, what do you use for this? It should be OK in a container that's sealed, or would I want some airflow into the unit?
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[vwkelso]

Well got a chance to work on it again today. I got the wiring all hooked up and the intake installed. Still need to do the cooling system, throttle cable, exhaust and a couple other small things. Today was awesome... after hooking wiring and fuel up it started on the first try Pretty sweet sound I'm stoked!!
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[ftp2leta]

Thanks for the info. Nice to see that RMW are nice to deal with.

Yes, SC bell-housing is nice. They put a lot of energy into this one. But i can't test it on some customer van, you guys are testing it On top most of my engine are from automatic car so no flywheel, no clutch. My adaptor plate are from Outfront and it's solid stuff, they use to make them for SC.

I'll give the bell-housing a try soon. My van could use a bigger clutch

Same thing with SC, i have a good relation with them.

Ben
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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

[vwkelso]

hey ben in those pictures is that coolant pipe also a res bracket? also what do you use for a hose coming off your t-stat if you don't mind me asking looks good factory like.
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[vwkelso]

It's a RMW mount a early style one. i'll try and get it to hit by prying and shacking it I think it's going to be ok though. I made my harness smallcar style and i think they set those up for under the seat. I would rather have it in the RR though, just need to see how the fit is may be to long? I will be using RMW SS exhaust again I am pretty sure it's a early style one, it is slightly used but I don't care... there going to tig on some updates to it on monday. But to tell you the truth I am not %100 percent how it's going to be set up, I'm just going piece by piece with this thing I guess i'll find out when I get the part Also getting throttle cable and coolant pipe from RMW next week. I just really really like dealing with the RMW crew everyone in that shop has a positive attitude and are very helpful, there just great to deal with! (it's also sweet that there right down the street )

Oh and I love how much room I have with this bell-housing it's amazing I could do a starter or pull the trans NO PROBLEM leaving the engine installed.
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[ftp2leta]

Nice job, i feel your happiness.

Mmmm... interesting, is that the Kennedy mount? Can you pry the engine, giant pry bar and make sure it's not hitting the Bell-housing. Or climb on it and jump on one side of the engine and ask your friend to have a look under.

A shorten oil pan will help for ground clearance.

I have a bit more angle on the drive axle (our only reference point):

It look like yours (not talking about the pan) is a bit lower... difficult to say. On top, the picture above show an 09 so they sit 1in lower then non VVT engine (99-04).

Just a suggestion if i may, think about the ECM location carefully. It's nice to have it in the engine compartment (the grey sealed box), unused space anyway, OBD plug close to engine. Mine is under the rear seat and it take space for nothing.

Question: what will hold you muffler?

I'm watching your thread.

Nice work so far, you must be proud.

Ben
_________________
Working with rust, grease, dirt and dust is a sad truth.
------------------------------------------------------
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

[vwkelso]

Ya I feel that it should be a little higher personally but I'm not really sure. I'm going to mess with the pan after I get it up and running properly. I haven't decided I was planning on either the smallcar or going with RMW. where dose the SC dipstick come out to make it a pain in the ass? Today was a really fun day for me was exciting getting her all bolted in! I was really amazed at how EASY everything has been. Next saturday I hope to put a few hours in on it and get the intake on, cooling system pretty much done, and mock up the harness. My coworker Derek has been helping me with everything witch has been a huge help, he's got a vanagon to.... may be doing another one of these thing soon I have a feeling
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[Franklinstower]

[SyncroChrick]

Today I drove a 1990 Syncro Westy with a 2.5.
The difference with my WBX is unbelievable.
I want one asap.

[vwkelso]

Oh and what do you guy's think about the engine height?
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[vwkelso]

Got the engine and trans all installed today. Got my coolant manifold back and you can see from the pictures it's going to work much better, where still going to do a couple tweeks to it though. Had to modify the carrier bar a little in the center due to bell housing clearance fixed it with a BFH and re-painted spot. That poder coat they use is some TOUGH stuff!! Clutch is all blead and working properly. Shift linkage and axles hooked up, locking diff act all hooked up... going really well.

one question i now have about a 1/4" clearance between the carrier bar and the bellhousing think that's enough? Can't see this thing flexing that much.

I am planning on mounting my ECM under the seat in the stock location so it should stay clean and dry. Thanks thummper for the positive words, after every step it gets easier and easier and more and more confident.

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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[thummmper]

YO KELSO!
man you are really doing a great job for your first. we learn the most on the first. Wheres that ecu going? will it stay dry?
don't let these guys rush you. I have been stumbling along since nov 1 2009. my trans shifter is getting reborn. I just got all the seals and the paint is drying under heat lamp now. my last section of shift tubing is all pretty now with new seals. I am just about to twist on my 2.2. She.s a beauty. Give yourself time to solve the problems as you go. I fealt overwhelmed at first, but each day I graduated to another level. It builds until you are ready to twist the key. good work. that black harnass lead with the red eyelet cable and the two grey and brown wires are energy for the diaperboxer alternator and the lic plate lites, that is, if they came thriugh the same hole as the ac hose to the condenser and are a little greasy. todd

[vwkelso]

OK So I took some notes on that manifold and stopped by RMW and talked with Mike about the part. There going to make some adjustments to it and tack it up TODAY and i'm going to stop by again in the morning and pick it up and test fit it. Where going to do this untill it's PERFECT so that way he can make a copy and if anyone wants to do this style conversion down the road he'll be ready for ya . I expected there to be a few small snags in this project but I think it's going to really be worth it in the long haul. I have to admit I really like the small car bellhousing idea but other than that there products don't compair to the quality of RMW IMO. There full conversion kit along with the rest of there products are proven work of art, I just have to be difficult and different and do it "my way" . I checked out some pictures online and the reason there manifold wasn't working for me was due to the gear reduction starter that the subie uses, if it wasn't for this it would fit like a glove. Check back tomorrow and i'll have some pictures of us fitting the engine into the van maybe some of yous' can get off on that
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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[vwkelso]

Well finally got around to doing some work on this thing. Was planning on installing everything into the van tomorrow but not sure if that's going to happen now. I am using the RMW Reversed coolant manifold with the SmallCar Bellhousing and the angle is off. You can see the outlet of the pipe in relation to the starter. This by no means is there fault they use the adapter plate and I am sure it's a perfect fit with the plate. Going to pull the intake asm off today and remove the coolant pipe. I am stopping by RMW tomorrow to pick up some parts, we'll see if it can be fixed tomorrow A.M. worst case it's going to have to wait till next weekend.

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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[vwkelso]

I know I know sort of dragging, but between being VERY busy at work and with the lady my time is limited. Just rented a place with my g/f so had put the rest of the parts on hold till next month. Pretty stoked about this place where moving into though, it's got a nice 3 car detached garage can't wait, been 2 years with no garage... Compressor, Welders, Drills, a place for all my tools yay!! Got this heater http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200329101_200329101 for christmas and I got 25 gallons of Kero for 50 bucks off a friend. I'm set Vanagon is a at work project i have a FJ40 i'll be finishing up at my place. Oh and I'm pretty excited to start my first buggy build... one thing at a time... one at a time

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86 Syncro
73 Westy
69 Sand Chariots Vaquero

[ftp2leta]

Come on men, this is getting long now, this van should be on the road by now
_________________
Working with rust, grease, dirt and dust is a sad truth.
------------------------------------------------------
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