H-6 3L Conversion

Team WorldTour · Posted: Sun Jun 05, 2011 3:01 am Post subject:

I have pics, but after a full day of work, then another 5 hours on the van, and getting home at 10:30 at night and spending time with my wife, pics will be posted as edits to the text as I have time. (Not trying to be rude here.)
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Team WorldTour · Posted: Mon Jun 06, 2011 12:19 pm Post subject: Day Nine...

Today was another workday, so I only got 4 hours on the van today.
I got the rest of the motor-mount bolts from Subaru today. I think they are still glowing....

After I got both the motor mounts bolted on, I tried to test fit Erics enging carrier. I panicked! I got scared! I got REAL pissed off! Evil or Very Mad

Then I realized I would have to loosen one of the motor-mounts in order to mount the carrier bar! Embarassed

After I got it mounted to the engine, I noticed this:

Image may have been reduced in size. Click image to view fullscreen.

No holes! I hope I drill it out right! I'm going to wait untill the tranny is attached to the motor, and the whole thing is ready to go in. Then I will mark and drill.

My co-worker came out again today. He's helping me track down a short-to-ground on the leisure battery. After poking around with the multi-meter, he asked me when I wanted to replace all the wiring. Shocked

He says he found so many shorts and broken wires, it's a wonder I'm driving at all!

So I guess the next project will be a rewire. I want a more modern fuse box in there anyway....

No clutch in the mail today.... Mad

_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Team WorldTour · Posted: Wed Jun 08, 2011 12:49 pm Post subject: Day Ten...

The pull-clutch I ordered finally showed up today Very Happy

!
It did not, however, come with a flywheel Sad

!
So I had to order one from Subaru Germany for 300Euro Mad

!
I have to say, I'm real happy and greatful for all the help, advice, and support of everyone so far! A big thanks to Eric for the parts, to RJES for the parts and advice, To Tom for the time difference phone calls on Sunday morning for tech support, and to Chris at Van Cafe for all the other parts to get this van ready for the new engine. Thank you, everyone!

I will be gone to Berlin for the week, so this is it untill Tuesday the 14th.
Stay tuned....
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Team WorldTour · Posted: Thu Jun 16, 2011 10:06 pm Post subject:

So I got the clutch in the mail, but it did not include a flywheel. I ordered a flywheel from Subaru, but they gave me a 270mm, instead of a 260mm.
I found one guy on base with a British-Spec Impreza with a pull clutch. I borrowed his VIN, and ordered another flywheel from Subaru. Maybe this time it will be correct.
I am still trying to find an O2 sensor for this motor, as there was one crushed one.
Tom/ Eric- Where does the downstream O2 plug into?
I've got most everything done, just waiting on that damned flywheel....
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Team WorldTour · Posted: Wed Jun 22, 2011 3:11 pm Post subject: Day 20

So, I picked up the flywheel from the dealer yesterday, and the damned thing fit! It was the right one! Finally!

So today I took the Subi motor off the engine stand, and mounted the flywheel and clutch to it.

As I lined them up, I was very excited!

And they went together like they were meant to....

Although, I am missing bolts. Was this part of the kit I got, or do I have to find those myself?
Anyway, Richard- The lower hole for the starter is threaded all the way through.

Is it meant to be like that?

Also, I pulled apart the CV joints and cleaned out all the old, crunchy grease.
Still waiting for my CV bolts.....
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Team WorldTour · Posted: Thu Jun 23, 2011 2:08 pm Post subject: Day 21...

So today I took my stolen CV Joint grease and re-greased my CVs.
After that, I got the farmer and his helper to help me push the van out of the barn and turn it around. You see, the barn floor is sloped. And the way I had the van on jack-stands, I had 25 inches of clearance under the bumper. The Subi, on the dolly, sits 27.5 inches tall.

So, after pushing the van up on ramps, I had 27.5 inches as well.

JUST fit!
I have some trimming to do.

This dolly is rated at 400kg. Just how much does this engine weigh?

I'm getting there. I just wish I had some help. It sucks doing this by myself.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Jake de Villiers · Posted: Thu Jun 23, 2011 2:20 pm Post subject:

When I did my Suby swap I just pushed the engine off the dolly and onto a piece of plywood, then shoved the plywood under the rear corner of the van.

I hear you on the help situation. I was able to get my older son to give me a hand with getting the engine/transaxle bolted up - that was a big bonus! Wink

_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com

thummmper · Posted: Thu Jun 23, 2011 8:24 pm Post subject:

when you are solo you can't be in a hurry. theres a tarantula in your van.
that rjs rig looks good

Team WorldTour · Posted: Fri Jun 24, 2011 11:28 am Post subject:

thummmper · Posted: Sat Jun 25, 2011 12:27 am Post subject:

you have been at this since november- it will be shocking to finally drive it- my first engine swap was may to the following february, but it is a real rock to drive now. I enjoy it almost every day. You are installing my most favorite japanese engine, one I had considered before, so I am really pulling for you on this. The mountain of things to do will end as quickly as it began. there's plenty of svx footage out there on utube, but no ez30 film, so watch the svx stuff and pretend it's your engine.
I just passed a year on mine, and still have far to go, but cool stuff happens every week. If I dont finish it, it will make a cool coffee table.[for giraffes]

Team WorldTour · Posted: Thu Jun 30, 2011 9:48 pm Post subject: Day 300....

I FINALLY HAVE THE MOTOR MOUNTED IN THE ENGINE BAY!!!!!

The suspension sits at 17inches.

Ok, a few issues:
Tom/ Eric- There seems to be an extra plug in the harness. Also, is the harness wired for the downstream O2 sensor?

Do I have to drop the tank to move the plastic coolant lines forward?
Can I use a heat gun to reshape the plastic coolant lines?

Eric- What size is the 'T' shaped fitting? Your instructions call for two to be used, however I can only find one in my parts box.
As far as the two small lines that tap into this bypass, I know one comes from the TB, is the other one the one off the intake itself? That looks like brake-booster/ vacuum line to me...
I can't think of anything else at the moment... more to come.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Team WorldTour · Posted: Tue Jul 05, 2011 1:36 pm Post subject:

HEY! DID ANYONE SURVIVE THE WEEKEND?

I got some real problems here!
As I stated above, I've got an extra plug in the wiring harness, no plug for a downstream O2 sensor, missing parts from my instalation kit (I've checked ten different places, this T- Junction 10/25mm does NOT exist in Germany!), also- where do they both fit in?

Ok, I also need to know how the intake goes together. From the parts I have I've decided- none of it will fit! (under the deck lid and in the firewall.) Do I have to drop the tank to move the plastic coolant lines forward? Can I use a heat gun to reshape the plastic coolant lines? Do I even want to try?

I also cannot find anyone who can put a flare on a 2" steel pipe!

But on an up note- I got the exhaust hung today!
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

levi · Posted: Tue Jul 05, 2011 2:00 pm Post subject:

I'm guessing these parts you're talking about are part of the kit from abercrombie?

Since you haven't posted pictures of these parts, could be only he can help with that. I for one would sure like to know what these parts are....
_________________
One of these days I'm gonna settle down,
but till I do I won't be hangin round.
Going down that long lonesome highway,
gonna see life my way

https://youtu.be/cSrL0BXsO40

Team WorldTour · Posted: Tue Jul 05, 2011 2:08 pm Post subject:

Yes, these are the parts from Eric.
Kit includes: hoses, pipes, nuts, bolts, seals, exhaust, carrier bar, hose connectors, and air box.

As a special one off, I also recieved: extra engine wiring harnesses, custom made (by Tom) main wiring harness, computer, and instruction sheet with photos.

All for the low, low price of: um, I don't know if he wants me to say....
Well worth it, in my opinion!

And aside from this one piece that is impossible to find a replacment for in Germany, the kit is complete and I have no complaints.

I just need some help on the finer points!
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Team WorldTour · Posted: Sun Jul 10, 2011 1:13 pm Post subject: Day 830...

Ok, so I have just about everything connected. I'm still having issue with the coolant lines. I got them moved into place, but now I can't get them connected. The rubber hoses have shrunk just a bit, and have gotten hard as well. It is impossible to get the cut ends over the plastis pipes now!

Also, I have no idea (nor can I find one!) how the fuel lines hook up. There are three pipes. One is fuel in, one is fuel out, and the other is evap? Which one is which? I went to hook up the battery today so I could put the code reader on it, and the starter cranked! The key was off, and the starter cranked! WTF??!!???

Eric, I REALLY need everything Tom sent you for the harness! I'm getting down to the wire here! I have to drive this creation to the final Scorpions concert on Saturday! In Schweinfurt!

Also, the clutch pedal moves 2 inches now.

Link

_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

Team WorldTour

I am really fucking pissed at the absolute lack of support I'm getting here.
I'm asking alot of questions, and I'm getting nothing back.
I started the van today. Engine runs great. I'm having an issue with the ignition wires, and the clutch wont move. I pushed on the clutch petal a little too hard, and blew out the plastic line.

If anyone still gives a fuck about my project, I'll go into more detail.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

GrindGarage · Posted: Sun Jul 31, 2011 11:26 am Post subject:

Man sorry to hear your troubles.

Can't imagine hitting the clutch hard enough to have the line blow!

I just got done my ej22 and sorting out the last couple of details can be very frustrating as there isn't a complete instruction manual for these swaps. Best to break out some whiskey and do some research. I found all the awnsers that I needed on benplace.com http://www.weidefamily.net/vanagon/ and smallcar.com

All the pics are a valuable tool. I know that this is a 6 banger but they are all from the same family.

What kind of issues are you sorting out now?
_________________
-cliff

91 Vanagon AUTO
97 Single Port EJ22 all smallcar.com

ALIKA T3 · Posted: Sun Jul 31, 2011 1:38 pm Post subject:

I give a shit about your project.

The thing is a lot of problems,people don't know the answer,or don't give a shit because they feel they know the answer,you gotta find it too.

I feel your frustration,I've been there on other projects,but be the change in this world:that's how I rule,I always post pictures,how I did it,helpfuls links,something that anybody can read and enjoy,so in the future the next fucker who tackle this project won't get as much frustrated as I was.

I've seen your dolly broken rated at 400 kg,but the weigh was not on 4 wheels,it was on 2 wheels and on the board,so the plywood cracked.If you had a steel plate,it wouldn't have cracked Wink

Bye

_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

Alaric.H · Posted: Sun Jul 31, 2011 3:06 pm Post subject:

Call me on skype and I will try to help you. Set up your video and we can share images. I am at Alaric.Hernandez

insyncro


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