Engine Conversion Owners

[Paul Bus]

Howdy all,

I had an idea the other night thinking about all the threads and engine conversion talks around here. With the good bad and ugly versions running around and the debates of which one is better and what have you. I am looking for real owners of these conversion to post there info in this thread. The info I am looking for is

Engine Type:

How many miles on donor engine and what year of make and model:

How many miles have you logged since conversion:

Gas mileage:

Cost:

Did you do this yourself or did you have a shop do it, if so what shop:

What types of issues have you run into:


This thread is not created to cause a pissing match !! I am just curious as to what the owners of these conversions have experienced real world. Maybe this list of info could help people make a better decision when they decide to make this leap into the conversion world or better yet put people in check with the reality of it all !! I am also looking into the longevity of these conversion and how they stand up against the waterboxer

If there is a thread that all ready covers this very specific request could you link it up and kill this thread.


Thanks for the input and knowledge of this site and the people who contribute

check out the stock thread for good info http://www.thesamba.com/vw/forum/viewtopic.php?t=431525&postdays=0&postorder=asc&start=0
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Whos got my heady westy

Residue for president !!

[GBA 88West LA]

EJ25 DOHC 2.5
06-07 Impreza 165-170 hp
14k mileage @time of install
3000 miles since install
mileage unknown
cost worth every penny
Pro Install Vanaru
no issues with install or motor at all, very clean professional product

intermittent stall on quick stops maybe 3x this summer if that, cant remember the last one

blew tranny 3/4 slider-upgraded to AA , seems to go thru stock brakes quicker, upgraded shocks & springs to accomodate, would i do it again> YES in a heartbeat
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88 Westy GL Vanaru 07 2.5 EJ25/AA Trans/oiling plates, 1.14 3rd-.77-4th..solar powered cabin

[Captain Pike]

I4 2.0 ABA block/1.8 Head CIS Injection
0. Ring, rods,mains replaced
Installed 1994. 200,000+
22 +
engine $200,Diesel doner van $400=$600
Installed by me.
Hall sender wire faliure.

[Volksaholic]

"Oh no... not another conversion thread!"

Engine Type: Subaru EJ251

miles, make and model:70k, 2001 Subaru Forester

miles since conversion:≈2k

Gas mileage:≈22 avg

Cost:Still haven't added it up... probably don't want to know. Around $5k for big ticket stuff, but it's the little things that I haven't added up.

Did you do this yourself: Self inflicted

issues: Only issues so far are an occasional OBD-II diag code 1507 and an overwhelming urge to take a long road trip in the van.

pd
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1988 Wolfsburg Edition, 2001 Subaru EJ251

[insyncro]

(5x) 1994 Subaru EG33 SVX 230hp 6 cylinder motors
various mileages motors from brand new long block to 100k mile donors
Small Car conversion parts
Tranmissions were all rebuilt at time of swap
Insyncro install and fabrication
donor parts cost $1500 - $5500

I have over 100k miles on my first SVX Syncro conversion
20-24mpg

Installing larger front brakes is a must with any van getting more than 200hp.

Best investment for any Syncro owner
Unlimited fun!

dylan

[Krautwagen]

Engine Type: Subaru EJ22

How many miles on donor engine and what year of make and model: 1992 Subaru Legacy (mileage was 50,000 when I got it in 2005)

How many miles have you logged since conversion: Not exactly sure because of the poor quality of the Vanagon odometers . 5 years in service, so probably around 50,000 miles logged.

Gas mileage: Again, not sure because of bad odometers and speedometers, but when I was able to calculate early on it was between 19-20 MPG.

Cost: Total cost of install was around $2500 (parts and engine/harness)

Did it all myself, even the wiring harness.

Issues: Subaru A/C compressor was bad, and ended up seizing this summer, got a good used one and now it cools really well. Strange idle problems, but does not stall at stops. Could use a VSS I guess. Also had a timing gear explode earlier this year, should have replaced them when I did the conversion in 2005. Leaking head cover gaskets replaced this year, now the block is clean and dry.

Here are a couple of pictures just after I got it all done in July of 2005.

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Andy
Lakewood, CO
1973 Type 1 Bug
1974 Type 1 Bug
1999 Eurovan MV

[jerrydog411]

Nice 1982 Diesel Westy

Bought it with conversion done by PO with outstanding documentation of whole process.

1.9TD AAZ brand new complete engine - ) miles prior ... 15K miles when I bought it .. now 76K so I have put on 61K

Plumbed & installed fan forced air intercooler @ ~ 23K - GREAT!

23 - 27 mpg depending on where / how I am driving

DK tranny was relatively unknown - blew up after ~25K & Daryl did a full rebuild.

Did an IP reseal ~ 15K ago .. LSD / USLD common issue

Did clutch prior to past February's big trip.

Run Bio whenever possible .. mostly B50; B75 / 99 / 100 whe I can get it from a reputable source.

Van has been well maintained as I don't like surprises. Only issues while on road trips ... serpentine belt (& I had no spare) - cost me an AAA , half a day and $18 and a 2 day delay and a new fuel tank in SoCall Jan '09.

Run ELF / Total 5W40 .. consumes zero and I would do it again in a heartbeat. Most consistently reliable vehicle I have had & it's been 4+ years so far.

As an aside .. anyone thinking of this as a conversion; I have the 24 page, fully documented conversion process Clint kept as a diary ... choosing, sourcing, vendoers, tools required, photos, costing etc available ... just pm me and I'll send it along.

Cheers,

John

[Destructo]

Engine Type: 2.0L 130hp Zetec Bostig Conversion

How many miles on donor engine and what year of make and model:
0 Miles, Brand new crate engine from 03 Ford Focus ZX3

How many miles have you logged since conversion: about 10,000

Gas mileage: 19-23mpg depending on weight, weather and road traveled

Cost: 6,000 in total with all bolt ons that didn't come with crate engine

Did you do this yourself or did you have a shop do it, if so what shop:
Did this one myself with no other experience for swapping an engine.

What types of issues have you run into: Since it has been running, I have had no issues whatsoever. There were a couple hiccups during install that were easily remedied (Alternator wire not plugged in, Bad TPS, Wrong Tune for ECU installed.)
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1985 Wolfsburg Edition Westfalia Camper Bostig conversion

Dude, where's your van?

[914 mike]

Engine Type: Subaru

How many miles on donor engine and what year of make and model: 120,000miles-1993 ej22 2.2L

How many miles have you logged since conversion: 50,000miles

Gas mileage:18-20mpg

Cost:@$3,400

Did you do this yourself or did you have a shop do it, if so what shop:Self installed. Wire harness by Tom Shiels

What types of issues have you run into: Zero

Transforms the vehicle. Get in and go without stress or worries. Have been from Baja to Banff and numerous places in between....
_________________
Mike
84 Westy
2.2 Suby
In a world full of ponies it's a thoroughbred horse....
Can ≠ Should

[whynotvw]

1987 syncro
1993 suby 2.2

140K miles
15k driven last one half years
$4.5k cost for conversion
-$1.2k recovery for selling my old engine.

17-19 gas mileage

near 0 issues.

so far Very happy.

[Williamtaylor33]

I have two vanagns right now. Both converted by the previous owner.
1st van-
Engine Type: iz/ahu tdi

How many miles on donor engine and what year of make and model: motor was rebuilt by po. Around 7k on engine.

How many miles have you logged since conversion: About 7k by PO/

Gas mileage:30 mpg on my one tank.

Cost: Came with the van.

What types of issues have you run into: headgasket blown/warped head.

2nd van-
engine type- 2.0 golf gti
How many miles on donor engine: new when installed- motor has 70k now.

How many miles have you logged since conversion: 70k by PO. 2k by me.

Gas mileage:18 mpg with driveshaft removed.

Cost: Came with the van.

What types of issues have you run into: none

3rd van (recently sold)
engine type- ford zetec
How many miles on donor engine: 1600 miles. $450 delivered to doorstep.

How many miles have you logged since conversion: 20k by me and more troublefree miles by new owner.

Gas mileage:18-23 mpg

Cost: 4200 for kit. 450 for engine. Another 400 for misc.

What types of issues have you run into: sagging motor mounts. (fixed with spacers..30 minutes worth of work), alternator died. Easy stuff.
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89 Bostig powered syncro westy

[dredward]

[edgood1]

Subaru 2.2 (EJ22 from '97 Impreza around 135hp) 1987 Syncro GL converted to full westy.
Engine had 14,000 miles at swap time.
3,000 since the conversion

MPG 18-24 decoupled.

mostly small car stuff except for the outfront adapter and flywheel.
stainless headers, J pipe, straight pipe and stainless muffler by SC. new mounts, custom air intake, reversed coolant manifold.

conversion and wiring done by me in a weeks time.

total cost was around $2000, all parts and engine were purchased second hand.

only problem was a defective hose clamp no the coolant reservoir, not Subaru related.
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia

[JPrato]

Subaru 2.5L from a 1999 Forrester
83 Westy 4 speed
134K on original motor but totally rebuilt it.
Bored next size over, new pistons/rings, rebuilt rods new bearings, new oil/water pump, polished crank, valve job, and timing belt/all rollers

All Small Car components and used their wiring documentation to do my own harness. Small Car code elimination board. SC Stainless Exhaust

All work except engine machining done by me.

Added PS, Subie cruise, and a Vintage Air AC at conversion time (I like pain)

1000k on the install, a couple of small issues: Too much travel on the clutch, had to add back a little air in to reduce it so that the clutch wouldn't bind at the end of the pedal travel. Works great now. (Small Car had heard of this on one other occasion) Bad Hall effect switch at install caused runability problems but cleared up with a new switch. Occasionally getting P1101 Neutral switch malfunction code (there is none), but running great otherwise. The engine intake noise is more than I like at full throttle/heavy load. I'm looking to add in some of the factory dampening measures back into the intake system. The noise is mitigated by the fact you are usually motoring up a hill, AT highway speed while it is happening.

20-21 mpg running hard up and down the hills of NY and PA, at highway speeds, fully loaded with the AC on.

Cost: $8,500 for engine rebuild, new PS rack/lines/coupler, AC unit and SC conversion parts. Donor engine worked out to be to be free as selling off the balance of the Forester covered the purchase cost.

As others have said the Subie conversion is great. This winter I will get the 4spd tranny re-geared to lower cruise rpms and better match it to the engine. I am also thinking about a 5 speed, either VW or the Subaru. I'm waiting to see how DClymer makes out
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Joe

87 Syncro Tin Top project
84 Westy, 2.5L Subaru power
06 Subaru 2.5 turbo in waiting
46 Cessna 140

[Dimitrios]

Engine Type:
(BOA) 2.9 V6 24v (1993)
How many miles on donor engine and what year of make and model:
88000 Ford Scorpio Cosworth
How many miles have you logged since conversion:
500
Gas mileage:
unknown
Cost:
3000 EUR
Did you do this yourself or did you have a shop do it, if so what shop:
DIY except wiring
What types of issues have you run into:
weak water pump need to add an inline electric
wiring harness is a real nightmare
exhaust fabrication
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Used Porsche 911 & VW 091 & 094 transaxles!!!

[DLJ]

engine Suby EJ-22 2.2
Miles unknown Japanese engine exchange
I have driven about 30k
Constant 17 MPG
Total including install about 7K (included all outer engine pulleys, belts, ect.)
Professional installed by Leon Korkin (Southern Calif.)
Initially had occasional starting issues, found that the alternator was shorting out ECU. Also added VSS. Now its perfrect. I would do it again.

1991 Syncro decoupler front and rear locker.

[HeftySmurf]

FWIW
I have gone almost 13k since june on my Zetec
paid 300 for a motor w/ 10k on it
Reliable as hell
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-Lorenzo
90 GL w/ Bostig

[Orbitald]

Engine Type: 1.9 AAZ TD

How many miles on donor engine:

And what year of make and model: 1987 Syncro Pass

How many miles have you logged since conversion: $15K

Gas mileage: 20-26

Cost: $3k for the new motor and around $2K in parts and stuff.

Did you do this yourself or did you have a shop do it, if so what shop: Did it myself

What types of issues have you run into: Runs a little hot on big hills in the summer.
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'87 Syncro Westfakia, 1.9TD ADE (AAZish), 068 Injection Pump, K03 turbo, 2.5" exhaust, Mercedes nozzles, SAAB Blackstone charge-cooler w/ 800cfm fan, Micro-1000 EGT sensor pre-turbo, boost at about 13psi, 235/70/16 with stock gearing

[DAIZEE]

Perhaps you all think this might not be important but I think miles on original tranny if original AND engine hours (if you have it) on the conversion. Also perhaps if you keep data on the vehicle (daily, weekly, mthly, etc...).

Just some ideas which I have found handy. Of course all that you've included in OP is necessary too.
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'09 2.5L Jetta 5 cylinder, 5 spd, super turbo, see thread in H2O Cooled Jetta, etc...
83.5 Vanagon L Riviera Model with 98 1.9L TD AAZ 4 speed Daily Driver 3 out of 4 seasons (sold)
84 Vanagon GL Wolfsburg Westy WBX 4 speed (sold)

[JPrato]

Daizee, for data, I keep a log book for the Westy just like I do for my airplane detailing work done, parts installed, basic maintenance etc. I don't record gas usage as it is pretty consistent and and I thought would just clog up the book. This along with the actual receipts gives a very good picture of the history of the van.
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Joe

87 Syncro Tin Top project
84 Westy, 2.5L Subaru power
06 Subaru 2.5 turbo in waiting
46 Cessna 140