Joined: 15 Jul 2008 Posts: 45 Location: North Lancashire, UK.
Posted: Fri Jan 16, 2009 9:53 pm Post subject: Swap this weekend !
Right, after about three months of planning and preparation my swap is on this weekend. I'm driving my 2.1 Syncro Kombi to Pete M's workshop tomorrow morning, and plan to drive it away on Monday with an SOHC EJ25 fitted.
Let the games commence ! _________________ 1990 VW 252 EJ25
1990 VW 246 AFN
Joined: 23 May 2006 Posts: 2527 Location: Mudway, Kent
Posted: Sat Jan 17, 2009 1:54 am Post subject:
Let the grins commence more like
Who's Pete M? _________________ 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"
Joined: 30 Jan 2006 Posts: 652 Location: North Staffordshire
Posted: Sun Jan 18, 2009 1:53 am Post subject:
Pete M is SyncroPete on the forums he uses. He runs www.syncroengineering.com, and has recently converted his EJ22 powered Syncro panel van to EG33 power (there's some footage of it's 1st run on Youtube, posted by andymcc. _________________ Regards,
Richard,
R J Engineered Solutions
Quality Subaru Powered VW Components
www.rjes.com
Joined: 15 Jul 2008 Posts: 45 Location: North Lancashire, UK.
Posted: Mon Jan 19, 2009 11:49 pm Post subject:
Sorry, been a bit too busy to bother about posting ! Got the new motor in yesterday and fired up first time on the button.
Spent all today sorting out cooling system, exhaust, throttle cable etc. Finally got it bled and running happy around 7pm. tonight, took a fair while for the thermostat to open. Didn't use RJ's crazy filling procedure ! Had to bleed clutch for some reason as it had gone soft.
First drive was WOW, this is a completely different vehicle. Very quiet and smooth at low revs, but an unearthly howl when booted.
Got home tonight down the M11 a darn sight quicker than Saturday morning going north ! _________________ 1990 VW 252 EJ25
1990 VW 246 AFN
Joined: 15 Jul 2008 Posts: 45 Location: North Lancashire, UK.
Posted: Fri Jan 23, 2009 12:29 pm Post subject:
The Kombi is still running fine, and still giving me a big grin every time I turn the key. I have to try hard to resist driving like a hooligan.. All I've done since the weekend is top up the coolant, as all the bubbles have now worked their way out, and checked there's no leaks or anything come loose.
Here's a batch of pics of the work so far. As you can imagine I was working flat out at the weekend, so didn't have time to take lots of photo's, and as it was dark when I finished, no chance yet to get any decent movies but I'll have a go this weekend.
There are still several bits that need more work:
Locate and fit a better inlet duct (the late 2.0l one I used fouls the bulkhead) - anyone got an early 2.2l one spare ?
Fit and commission the cruise-control system
Complete fitting and commission the LPG system
Get and fit a better sump, planning to get one of the new Smallcar alloy ones
The pics, first off a couple showing the engine as I was prepping it. You can just see the LPG injectors at each side of the manfold. I have some clearer pictures of this somewhere which I'll put up:
From the side:
Next, a couple of pics of the wiring cabinet I'd completed prior to the engine installation. I didn't have any problems at all with the wiring, as I found a copy of the factory manual on a Russian website. The engine fired first turn of the key, which was very satisfying ! I'm using an ignition relay switched from the VW key, I can start the van from the VW key or the Subaru key. For normal use, I just leave the Subaru key in the 'run' position, and use the vehicle as normal, or I can remove the Subaru key, and the vehicle is immobilised. For the hot and switched power, I've maintained the same grouping of the various parts of the system as they were in the Legacy, and the same fuses. They are labelled, so for troubleshooting it should be possible to follow the Subaru factory manual.
Next, a couple showing the engine built up, mounted onto the Smallcar adapter bracket, and attached to my spare AAN gearbox:
Out with the trusty old Wasserboxer:
Finally a shot from underneath after the new engine was bolted in, showing the Smallcar engine bracket and exhaust header:
Joined: 23 May 2006 Posts: 2527 Location: Mudway, Kent
Posted: Fri Jan 23, 2009 2:28 pm Post subject:
S W E E T wiring install, lovin that fella _________________ 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"
excellent work.
Love the dual key idea...youve just solved a problem for me
Also whose LPG kit did you use in the end? how was it/service/ quality etc?
Joined: 30 Jan 2006 Posts: 652 Location: North Staffordshire
Posted: Thu Jan 29, 2009 5:57 pm Post subject:
Nice to see it in the flesh last weekend Andy. Sorry I only had 10 minutes to spare before going out. One of the best 'attention to detail' installations I've seen. Nice one.
My engine was nearly as clean as yours when I installed it years ago. I wish it still was! _________________ Regards,
Richard,
R J Engineered Solutions
Quality Subaru Powered VW Components
www.rjes.com
Joined: 23 May 2006 Posts: 2527 Location: Mudway, Kent
Posted: Thu Jan 29, 2009 6:12 pm Post subject:
Who's make of header is that? Any details please? _________________ 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"
Joined: 15 Jul 2008 Posts: 45 Location: North Lancashire, UK.
Posted: Thu Jan 29, 2009 6:40 pm Post subject:
Hi all,
Thanks for the comments, I'm very pleased with how it's turned out, but there's still a bit to do before it's finished.
The LPG system is Bigas SGIS purchased from Tinley, who were pretty good to deal with. It all looks to be decent kit, but it's not fully commissioned yet so await a further update. All I've done so far is fit the nozzles and injectors to the inlet manifold.
The exhaust header and J-pipe was from Smallcar in the States. It was ordered back in July 08 before RJ's was available. If it had been I may well have gone for that. I'm using a VW-pattern muffler from Ernst and a VW Syncro tailpipe. I do get a fair amount of rorty sound effects when booted, but a lot of that is induction noise. After I've replace the cheapo cone filter with the Subaru airbox it should quieten down a bit.
RJ, that rattle was quickly identified as a loose lambda probe, when I tightened it the over-revving at start went away too. _________________ 1990 VW 252 EJ25
1990 VW 246 AFN
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