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My EJ22 swap - Projects appear smaller in mirror
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Farfrumwork
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PostPosted: Thu Oct 08, 2009 12:01 pm    Post subject: My EJ22 swap - Projects appear smaller in mirror Reply with quote

I wrapped up my swap back around mid June. It consisted on rebuilding a '92 Subaru EJ22, and fitting it to my '85 Wolfsburg. I did all the work myself at home, including the wiring harness.

I used a combination of conversion parts, but the bulk of the goods came from SmallCar. I used the now-not-so-new new cast bellhousing, which really is well done and makes the install look almost factory.

I'll make my thanks up front then get to the pictures.
The following people and shops really helped me along through advice and/or prompt service (in no particular order):
*mblotz - my local swap master (and giver of exhaust)
*SC - great service and sweet parts
*Outfront MS - awesome service and an oil pan that withstands LARGE rocks (ask me how I know... Twisted Evil )
*EVERYBODY on the subaruvangon group - Sooo much knowledge.
*Superupair in Boulder - thanks for the deals.
*ChesterKV and Ranchero - great threads with lots of pics, which were very helpful.
*The Weide family - You made my harness possible, period.
*My family - thanks to my wife and son for helping me out.

And finally, NO THANKS to burley motorsports Confused Mad


So anyway, enough gushing. ON WITH THE SWAP!

-Chad
ps- please forgive my spelling/typos. I'm an engineer not a linguist.


Last edited by Farfrumwork on Thu Oct 08, 2009 1:54 pm; edited 1 time in total
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Farfrumwork
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PostPosted: Thu Oct 08, 2009 12:01 pm    Post subject: Reply with quote

So I started with a stripped EJ22 from a '92 Legacy, with a reported 16x,xxx mi. It was completely apart and hot tanked, and I had never heard it run nor did I know the seller at all. It also had a COMPLETE wiring harness (every single thing attached). I paid $275 for it all so I figured it was a deal anyway it turned out.

boxes of a motor
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and a harness
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I don't know if you can see it, but the bores still had cross-hatching -sweet
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Then onto the stand
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Looking more like a motor now
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I sent the injectors out for cleaning/flow test. They even replace all the o-rings and pintle caps - Whichhunter injector service rocks!!
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While everything was apart, and had been pretty well cleaned in the hot tank, I took the time to paint the valve covers and intake spider. Ceramic paint. Me likey
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I had replaced every gasket and did the TB/H2O punp/etc... It's normal fare so no pictures, but here's the motor mostly complete. And the painted spider too Cool
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Then on to the harness while I waited for my tax $$ and more components.


Last edited by Farfrumwork on Sun Oct 11, 2009 3:25 pm; edited 3 times in total
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Farfrumwork
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PostPosted: Thu Oct 08, 2009 12:01 pm    Post subject: Reply with quote

So, again, I started with this
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The started laying it out and getting a feel for what's what. I drive a '93 turbo-Legacy in my daily life so I know the motors pretty well, and had a subject to look at while figuring out various things.
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Yes, I overtook my wife's sewing area... Laughing
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Copious amounts of painters tape. Label label label!
*note box of refuse harness - it ended up weighing 10lbs.
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Finshing up out in the livingroom.
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The little piece of paper that was priceless (yet it was FREE!!)
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I can't believe I don't have a picture of the fully complete harness by itself (all accordian wrapped and taped). I'll look around some more for that. You'll see parts of it later in the final push section - mounting everthing int the Vanagon.


Then it was time to pull the stock 1.9l. I can't say I was sad to see it go, but man did that little motor give it's all. It would run at 8/10ths all day, and probably still is (I sold it to live on in another '85 Wink )


Last edited by Farfrumwork on Sun Oct 11, 2009 3:26 pm; edited 4 times in total
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Farfrumwork
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PostPosted: Thu Oct 08, 2009 12:24 pm    Post subject: Reply with quote

In to the garage went the subject. It barely fit.
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Last "drive", piloted by my son and co-piloted by the neighbor kid
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The workspace
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Yea 'ol wasserleaker
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Then drain, drain, drain

Look what we have here... typical fine metal particles in the tranny fluid
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SHE'S OUT
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Then I separated the tranny/ motor and fit the SC bellhousing to the transmission and filled with Redline MT90.
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Motor with a moustache and FW/clutch installed.
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transit to tranny land (and I'm not talking Trinidad CO)
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Coming in
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YES
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My own private lunar landing "we have touchdown"
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Lots of this
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Then in went the harness, and the countdown to key-turn is near.


Last edited by Farfrumwork on Thu Oct 08, 2009 9:22 pm; edited 4 times in total
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Farfrumwork
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PostPosted: Thu Oct 08, 2009 12:38 pm    Post subject: Reply with quote

Since this is an '85 I don't have the stock ECU location under the rear bench - it was in the engine bay behind the pass tail. I enlarged the AC hole (AC has been gone a long time) and mounted it under the rear cabinent -out of the way yet accessible.

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I mounted the Subie ECU on an AL tray I whipped up
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And I mounted the tray to an existing bolt under there
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I better view of the bulk of the harness exiting the compartment (I later fixed it to the wall more to be secure and out of the way)
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My Family inspecting the progress so far. They like it, and they LOVE "Campy" (My son named her when he was ~3)
Thanks Guys!!
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SS Smallcar header and my basically free 2.1l exhaust (painted in 2000F ceramic paint too - clean as a jelly bean)
drivers side
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pass side
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Laying on the concrete - I like that sort of thing
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rear view - can you say Clearance?!?!
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Ta-Daaaaaa!!!!!!!
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And then she was out
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Those are new to me stock 14" alloys (which I also painted - Duplicolor wheel paint , silver) wrapped with 27" Grabber AT's. I have more pics of the van and the maiden voyage we took just days after she ran.
More to come - I need to go pick up my son from school Very Happy


-Chad


Last edited by Farfrumwork on Thu Oct 08, 2009 1:22 pm; edited 2 times in total
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syncrosimon
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PostPosted: Thu Oct 08, 2009 12:49 pm    Post subject: Reply with quote

That's really nice work. More pictures please.
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markmc90
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PostPosted: Thu Oct 08, 2009 12:54 pm    Post subject: Reply with quote

Yes more pics please. Did you keep track of your costs? I'm curious what your total was by doing all the work yourself.
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wasserbox
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PostPosted: Thu Oct 08, 2009 1:23 pm    Post subject: Reply with quote

Farfrumwork wrote:

transit to tranny land (and I'm not talking Trinidad CO)


Heh. Heh Heh.

Gotta love Co Only jokes...

Looks good. I would have been a little (lot) overwhelmed to get an entire engine in 10 separate boxes.
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Farfrumwork
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PostPosted: Thu Oct 08, 2009 2:25 pm    Post subject: Reply with quote

Thanks guys.

Total approximate cost was $2700 or so. That's with selling the 1.9 for $300, but not including the new wheels/tires, but I still have a couple hundred $ worth of spares to sell too.
Around $3000 is where it should be.

Here's some of the maiden voyage. It had run about 20mi before we took off for southern WY. Nothing like an unproven setup a couple hundred miles from home Rolling Eyes Cool

This was on the summer solstice Shocked
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which is also my wedding aniversary (good thing all was working well Wink)

"WE MADE IT"
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with NO issues I might add.


A few weeks later - outside Nederland
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Those tires are killer!
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Another trip, this time to the Leadville area
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Landed some big fish!
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Then over Weston Pass on the way home (12,000). Mostly easy, save one section that was tough -it took 3 tries to get through it and it scarred 2 a-arms and put a nice dent in the seam off my oil pan (just cosmetic)
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The new found thrust of the Subaru motor is a great and rewarding feeling. It really makes driving up here at altitude enjoyable (I live at ~5500' ASL, and drive to 10-12,000' on almost every van outing).
There's always more to do, and I have a list of mods to perform, but I'm sure you ALL undestand that. Smile

Like this - Here's the side shot after I made and installed some rear spacers (saggy butt syndrome)
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She rides at just under 18" (center wheel to arch) and I have ~10.5" of clearance under my oil pan/

Later
-Chad
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markmc90
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PostPosted: Thu Oct 08, 2009 3:05 pm    Post subject: Reply with quote

Thats great to here that your swap went so smoothly. Could you guess at how many hours you spent on it. Mostly the harness is what I'm curious about.
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campism
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PostPosted: Thu Oct 08, 2009 3:26 pm    Post subject: Reply with quote

Nice work! An inspiration to those of us itching to tackle a job like that.
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Franklinstower
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PostPosted: Thu Oct 08, 2009 3:31 pm    Post subject: Reply with quote

Great Job - looks excellant!

did you put new rings on the pistons? what did you do the heads if anything and do you know what your compression numbers are now? I too did the '92 EJ22 swap all by myself, but the engine had 102k on it so I only did the TB and rollers, cam seals, crank seals, water pump etc.

thanks,
Paul
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Farfrumwork
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PostPosted: Thu Oct 08, 2009 4:27 pm    Post subject: Reply with quote

Hours? hmmmm I'd probably rather not think about it HAHA. I did it over the course of many months (working on the donor motor 1st, then into the van).
The harness was probably 15-20hrs I say.

As far as the "rebuild", I guess that's a overused term. I really just "re-sealed" it, new headgasket, all seals and gaskets, TB, tensioners, H2O pump etc... I didn't even go into the oil pump as it was sealed well (no loose screws)
It was kind of a gamble as is, but I rolled the dice and it really does run VERY good. I plan on a frankenstein motor in 3-4yrs (2.5l bottom end/2.2l heads - keeps all the wiring the same) anyhow, but I bet this motor will go quite a while. I want a Syncro transmission first anyhow (or maybe at the same time?)
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insyncro
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PostPosted: Thu Oct 08, 2009 5:48 pm    Post subject: Reply with quote

Nice post.
Thanks for documenting with photos.

dylan
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PostPosted: Thu Oct 08, 2009 6:01 pm    Post subject: Reply with quote

Very nice write up and photos. Thanks for sharing. Especially liked the photos of Weston Pass. I haven't across it in years. Need to get back down there. I have no excuse, its just too close.

I have a grin on my face ever time I drive my '91 EJ22 powered '89 Westy and its been a year since the conversion.

You in Denver?
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Bruce Wayne
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PostPosted: Thu Oct 08, 2009 6:13 pm    Post subject: Reply with quote

very nice work. wish I had the knowledge to do that.
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PostPosted: Thu Oct 08, 2009 9:06 pm    Post subject: Reply with quote

Great job. Enjoy the heck out of it. Very Happy
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PostPosted: Thu Oct 08, 2009 11:50 pm    Post subject: Reply with quote

Farfrumwork wrote:
Hours? hmmmm I'd probably rather not think about it HAHA. I did it over the course of many months (working on the donor motor 1st, then into the van).
The harness was probably 15-20hrs I say.

As far as the "rebuild", I guess that's a overused term. I really just "re-sealed" it, new headgasket, all seals and gaskets, TB, tensioners, H2O pump etc... I didn't even go into the oil pump as it was sealed well (no loose screws)
It was kind of a gamble as is, but I rolled the dice and it really does run VERY good. I plan on a frankenstein motor in 3-4yrs (2.5l bottom end/2.2l heads - keeps all the wiring the same) anyhow, but I bet this motor will go quite a while. I want a Syncro transmission first anyhow (or maybe at the same time?)



Man ... you are THE Hombre as my gringo friends would say. I am very impressed. Beautiful van and if I may say beautiful family. Great pictures. My top off to you.....
As you mentioned it I guess it will not be considered off topic, but I am most interested in any info you may have on that 2.5 with 2.2 heads. The 2.2 in mine performs just fine but with mileage unknown and a rabelaisian appetite for motor oil I guess I will have to confront his problem sooner or later and ****to me*** the 2.5 with 2.2 head will be the way to go.
Thanks for the post
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ftp2leta
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PostPosted: Fri Oct 09, 2009 5:21 am    Post subject: Reply with quote

Harnesses... wires wires wires...
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I'm impress, bravo! On top, your harness is one of the hardest to do, i real spider web compare to, let see, an 2003-04. I admire you, very nice job, and it look like it was fun also. Beautiful family you have there.

Don't worry about the bottom end of that 2.2L, it may last longer then the van itself.

Using a 2.5L short block with stock intake/FI will only give you a bit more torque.

A nice but rare 2.2L conversion is the very late (third phase) 2.2L, it as 2.5L heads. About 145hp. But no one is using that engine because it's somewhat unique.

I just finished my 35th conversion yesterday, an 09 engine with 07 electronic.
http://www.benplace.com/bertrand_subi1.htm

Cheers, Ben
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mblotz
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PostPosted: Fri Oct 09, 2009 6:08 am    Post subject: Reply with quote

greetings from medellin, but--when we racin up the pass? ill even tow dirt bikes to keep it fair
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