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2.5 SOHC Conversion Journal
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vwkelso
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PostPosted: Sat Oct 24, 2009 12:29 pm    Post subject: 2.5 SOHC Conversion Journal Reply with quote

What the heck sure some might find this interesting. Got a 2.5 out of a 2001 Legacy 90k ran great. Replaced head gaskets, VCG, Plug Gaskets, VCG Bolt seals, cam and crank seals, dipstick tube o-rings, Fill tube o-ring, Oil pump o-ring and re-seal, Coolant manifold o-rings, T-Belt, ALL Rollers, W-Pump, T-Stat, Ten asm... sure I missed some stuff but you get the point, the inside of that engine was VERY CLEAN well maintained. Sorry no pictures of the engine rebuild not that exciting. (Oh and what about that torque sequence for the head bolts... torque torque loosen loosen torque torque etc.. huh weird I thought?) Placed smallcar order for bellhousing, Stage 2 clutch, VSS, ECM Chip, and couple other small things. I am going to use smallcar bellhousing along with Rocky Mountain Westy engine carrier, exhaust, coolant pipes, P/S hoses etc. Think this will turn out pretty nice, I am pretty sold on the bellhousing or else I would have gone 100% RMW, IMO you just can't beet there quality and level of support A+ crew!! I'll be working on my harness this week and will be posting some pictures along with that.

Schony
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climberjohn
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PostPosted: Sun Oct 25, 2009 10:01 am    Post subject: Reply with quote

Sounds good, keep us posted!
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PostPosted: Sun Oct 25, 2009 10:13 am    Post subject: Reply with quote

Does the RMW carrier fit with the Small Car bellhousing? I thought there was some issue where the bellhousing moves the motor more forward in the engine bay? Maybe I'm wrong, just going from memory. But curious none the less because I thought the RMW was designed with an adapter plate in mind.
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Rhinoculips
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PostPosted: Sun Oct 25, 2009 1:02 pm    Post subject: Reply with quote

joeldella wrote:
Does the RMW carrier fit with the Small Car bellhousing? I thought there was some issue where the bellhousing moves the motor more forward in the engine bay? Maybe I'm wrong, just going from memory. But curious none the less because I thought the RMW was designed with an adapter plate in mind.


From what I understand, the SC bellhousing keeps the engine in the same location as if it were installed with an adapter plate.
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vwkelso
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PostPosted: Fri Nov 13, 2009 2:10 pm    Post subject: Reply with quote

OK So I got half my parts here are some pictures. Small Car bellhousing kit Stage 2.5 clutch/pp/fly, speed sensor. All parts look very good quality. I am now working on my harness and wow what a job, I have about 7.5 hours into it now and have probably 3 to 4 more to go. When doing this harness I STRONGLY suggest getting a good pair of Dykes I started off using a pair of MAC's that came with a kit and they suck, Went back to work and got my Knipex long dykes and was much better. I have BLISTERS on my hands from doing this wiring lol. I will post some pictures of the wiring this weekend sorry don't have any pictures of harness before I started .... was just a full subaru car harness nothing special. Oh and did I mention what a PITA it is to get this thing organized!?!? Confused Should have my RMW parts by end of the month, i'll keep ya posted.
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vwkelso
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PostPosted: Fri Nov 13, 2009 2:15 pm    Post subject: Reply with quote

forgot about the pictures LOL



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Yes I know the motor isn't 100% back together but u get the point
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vwkelso
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PostPosted: Sat Dec 05, 2009 7:40 pm    Post subject: Reply with quote

Been going good, just taking my time been busy at work. So I got the harness done I think it looks pretty good and am confident it's all correct. The one thing I am wondering is if it's to fat in the center... it's about 2". It was a pretty tight fit getting that stock harness out today, that tin behind the "black box" is sort of a PITA seams that maybe I should notch that a little bit to avoid that bend? Another thing what is the section of harness that goes up behind the left C piller used for? And how about the black C/M behind the right tail light? Here's a few of the harness work, will post some engine removal photos early next week.

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vwkelso
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PostPosted: Sat Dec 05, 2009 7:42 pm    Post subject: Reply with quote

couple more
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PostPosted: Sat Dec 05, 2009 8:35 pm    Post subject: Reply with quote

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What I was going for....


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PostPosted: Sat Dec 05, 2009 9:00 pm    Post subject: Reply with quote

wow nice, want to do my harness next?
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PostPosted: Sat Dec 05, 2009 10:14 pm    Post subject: Reply with quote

Good job man! Everything looks great so far, keep it up!

The RMW crew is some awesome guys to do business with huh? I'm having a great experience with them. My svx conversion parts got packed up and shipped yesterday, should be getting them very soon Very Happy
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vwkelso
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PostPosted: Sun Dec 06, 2009 8:33 am    Post subject: Reply with quote

Thanks, and yes they are very cool. I think I may have saw your conversion parts all laid out yesterday while I was in there talking with Mike. Guess he's got a CNC Plasma table on the way, i'm sure they'll be getting creative with that Wink. Think I figured out what those sections of wiring where for, behind the right tail is the Idle air control box I think, and the wires going up threw left c pillar are for my A/C and blower.
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PostPosted: Sun Dec 06, 2009 11:42 am    Post subject: Reply with quote

Quote:
The one thing I am wondering is if it's to fat in the center... it's about 2". It was a pretty tight fit getting that stock harness out today


Hi hi hi, in a good way Smile

Ben
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vwkelso
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PostPosted: Sun Dec 06, 2009 3:02 pm    Post subject: Reply with quote

Quote:

Hi hi hi, in a good way Smile

Ben


What do you mean... don't get it? It's to fat, going to be a PITA er what? Never done this b4. Laughing
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PostPosted: Sun Dec 06, 2009 3:38 pm    Post subject: Reply with quote

vwkelso wrote:
Quote:

Hi hi hi, in a good way Smile

Ben


What do you mean... don't get it? It's to fat, going to be a PITA er what? Never done this b4. Laughing


Just kidding, well, 2in is a bit on the FAT side Smile

But wires are wires, the way you routed them is the reason it's a bit big, but that won't affect at all the operation.

It all depend where you put the ECM/ECU and the way you route OS wire and bla bla bla...

Your doing a great job. I have great respect for DIY.

I see nothing wrong with your conversion so far, keep the picture coming, if you have any question i will follow your thread.

Here is a picture of an 03:
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On those i route the OS wire separately because my ECM goes behind the right tail light.

Another shot, in this case junction box harness and main harness are together.
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Cheers, Ben
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vwkelso
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PostPosted: Sun Dec 06, 2009 4:19 pm    Post subject: Reply with quote

Cool thanks man, On your harness the center wire with the red rubber stud cover, blue connector and small gray connector this is the Alt and A/C connector right? I don't have the alt post terminal on mine... is this positive for ECM, why dose alt go to ECM? I hope I added a prevision for this with my To Vanagon wires.

And on hindsight I should have considered the behind R/T light for the ECM location. I think I might have to do a little cutting to that tin behind the black box and maybe make the hole under the seat a little bigger.

The next step as of today is to figure out the vanagon wiring. The Engine harness is out, just need to figure out what's what of the leftover.

Schony

Oh and I like your web page, informative, looks like you've got a lot of nice job's under your belt!
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PostPosted: Mon Dec 07, 2009 6:34 am    Post subject: Reply with quote

Hi and thanks.

Yes it is (center wire)

Power from ALT goes to Relay (relay and ECM are together in a sealed box), IGN + from junction box to fuel pump relay AND ECM, but it's been a wile that i did an 00-01 Smile Still, it's always the same principle.

In the VW harness you need to keep the rounded connector that was in the black junction box, it as several wire but i don't use them all. But again, it all depend on YOUR setup.

But i'll tell you the major one (in junction box and not on harness):

Single yellow connector with black wire is: Ignition + (often as a 5 amp fuse), goes to ECM and fuel pump relay

Single yellow connector with blue wire is: ALT light in dash, this need to go to ALT directly (grey or green plug).

Main rounded connector:
Yellow/red is: temperature gauge in cluster, goes on the reverse manifold temp sender. If you use the Subi sender you need a .28 OHM resistor.

Red/black is: Your Start Signal, goes to ECM

Green / w shield OR blue/w black on earllier model is: Oil pressure, this wire can be found in main harness but very close to engine main plug

Green is: RPM, goes to ECM

Bizarre blue green/blue is: Expansion tank sender.

Brown is a ground, i don't use it, it's old and always give me problem, i built my own ground.

Yellow center of plug is: I don't remember and never use this one.

So, find the female side of the plug in the harness and the EX tank plug and wire. That is all you need in the old harness.

Ben
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vwkelso
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PostPosted: Mon Dec 07, 2009 11:15 am    Post subject: Reply with quote

Some engine removal pic's.

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vwkelso
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PostPosted: Mon Dec 07, 2009 11:16 am    Post subject: Reply with quote

Oh and a quick question... Do I remove the tins around the engine bay for the subie motor? Or do I just leave them alone?
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PostPosted: Mon Dec 07, 2009 6:13 pm    Post subject: Reply with quote

vwkelso wrote:
Oh and a quick question... Do I remove the tins around the engine bay for the subie motor? Or do I just leave them alone?


Remove them, they need to be modified Smile

Sorry, no good picture of that.

Ben
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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
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