T25 Multivan - subaru installation

[mike1978]

I`m pretty new to all this alternative engine stuff but i thought i`d post my efforts up here

i had a bay window camper project on the go for a while, but with moving house and suffering with a bad back, its had to go and the money is going to fund a subaru conversion to my daily driver -an LLE multivan.

Here he is - the willing participant





and looking at an ominous package thats arrived! -



lo and behold, its a an EJ20 subaru impreza engine!-



The vans current engine is a very tired and smokey 1.6 TD - its done 320000km, so i think its due for retirement and the scooby should add a bit of extra spark to my vans performance

i could`ve gone for the 2.5 litre, but decided on a 2.0 for fuel economy and its newer than most 2.2`s - this one is from a 98 subaru impreza.

this also came with the engine - a scary box, thats looks like it should belong in an alien film -



i started by stripping down the engine - unfortunately alot of the bolts and pipework is a bit rusty - i think the donor car may have been involved in a n accident and the battery split spillng over the engine. nevermind, i`ll soon get them sorted out.

here`s the inlet manifold -



i`m going to be using the rjes bellhousing and his services for the wiring, so i spent most of this afternoon preparing the loom for richard to dissect and remove the necessary bits -

initially -



after a few hours work removing the insulation and cable tieing it up, i`ve been left with this -





next step is to clean that engine up a bit!

[doppelganger]

dishwasher
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vwdrc AE bugjam winner
11.23@127mph. 1.47 60ft. 2.85sec 0-60mph

[mike1978]

[doppelganger]

well i can think of at least one reason to get one
_________________
vwdrc class rep




vwdrc AE bugjam winner
11.23@127mph. 1.47 60ft. 2.85sec 0-60mph

[ElusiveStranger]

Hi Mike

Ummm, '98 eh - crossover (probably) like mine.
You're prolly gonna need a VSS, I did!

Please don't use that hammer (background of one of the photos) to take the engine apart!

Nice bus
_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more
Bugger, missed out on "Live fast, die young"

[mike1978]

don`t worry - the hammer hasn`t been used in anger yet!

i did wonder about the VSS - i guess i`ll have to wait until i fire the engine up and drive it to find out about that.

away this wkend so not much will be done i guess until next week now. i`m going to get all the pipework, bolts etc zinc plated at a local blasters.

[ElusiveStranger]

You appear to be missing an alternator bracket, black one shown here on LHS of the alternator



_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more
Bugger, missed out on "Live fast, die young"

[mike1978]

i do have power steering pump to be fitted - will take a look at the various brackets i have tomorrow.

was away last weekend, so didn`t get anything done, but i have got the wiring loom and coolant manifold sent off for conversion - other than that i `ve been mostly cleaning bits and pieces.
i got the injection pipes and various metals bits bead blasted and they`re ready for a fresh coat of paint.

i was out all yesterday too, but took advantage of having the day at home today to remove the current engine from the van - never done it before - what a job and a half! i`ve removed planty of lawn mower engines, but this was a different kettle of fish - i had to get all the water pipes undone and loose, and the power steering pump bits too. then all the nuts and bolts had quite a few years of rust and i`ve never seen such an oily engine!

i hired an engine crane to help me a bit, but still struggled because the current 1.6TD is mounted on an angle and the centre of balance is all over the place. anyway, eventually got it out - knackerd now, but just glad its over and i can relax with a beer now

i`ll get some photos up tomorrow if possible - my camera has been playing up a bit. will be putting the old engine on ebay too i reckon.

[mike1978]

finally got the camera sorted!

here`s the current engine sitting in there -



once removed and a few harsh words directed at the engine, you get this -





and a very heavy dirty diesel engine -





that thing weighed a tonne - it took 4 of us today to lift it into the back of a van!

anyway, i`ve also been cleaning the donor scooby engine up. here it is in its current state - after lots of gunk, wire brushing and a fresh coat of paint -

looking a bit better



pretty clean under the valve covers too -



i have to admit, ive gone a bit boy racer ish here and sprayed the injection pipes red!



hope it doesn`t look too chav when i`m done!!

next step is to get the engine up into place then i can start getting an exhaust system together.

[ElusiveStranger]

You'll be wanting to know the valve clearances then:
Inlet 0.2 ± 0.02
Exhaust 0.25 ± 0.02
_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more
Bugger, missed out on "Live fast, die young"

[mike1978]

thank you very much

you would`nt know a website with the torque settings on for thing s like the clutch and other such bolts by per chance?

[ElusiveStranger]