If you've been following me here and on thesamba, you'll know that this project got complete wrapped around the axle when the engine was found to be a completely worn out dud.
A hiatus of four months...that can't be good. Actually it has been the worst see-sawing I've ever done on a project.
My policy, when I started this project, was to make a nominal effort to get the Type4 engine running. I dumped $450 in parts and diagnostics into it performing that effort, including new injectors (the old ones were glued shut) and a whole host of other items. All for an engine that I should have just pulled out and kicked to the curb. But you don't know until you try, so I tried.
Having wasted a few months working when I was able to, I discovered that I was the proud owner of a Type4 shaped boat anchor; I should have punted then. The intention was always to go Subaru power if the Type4 wasn't recoverable.
Instead, I let myself be lured by the siren song of "keep it stock." You know the ones: "You'll be sorry." "You'll never finish." "You're a butcher." "The Type4 is the finest engine VW ever made." "You're killing your resale value." "Oh god another hack job..."
Nuts. I got in completely over my head with a Type 4 rebuild, and then discovered that I couldn't even get good parts for the rebuild. So around Halloween, I said to hell with throwing good money after bad and I've been going great guns toward a high and tight Subaru installation by my own hand, using products I've sourced myself. The purists are welcome to polish their Bulli with a diaper. I want to USE mine.
Now that I'm done with my screed (pant, pant, pant) we're going to get on with the job of performing the conversion. All products below are either used or manufactured new in the USA. No VAT. No killer shipping. Most items are COTS (Commercial, Off-The-Shelf.)
Conversion Specs:
- OBD2 compliant 1997 Subaru EJ22 (137 ft./lb. Tq - 145 HP.)
- Gasket kit to reseal engine from its present leak points (oil pan, cam bores, valve covers, oil breather tower plate.)
- Wiring harness conversion by Jeff Robenolt (jrobewesty)
- Cooling: Dual A1 525mm Radiators in engine compartment, air dam / bracket support. (Battery relocated to under rear seat. See JMSkater and Mild-Core design here on thesamba and on STF.
http://www.thesamba.com/vw/forum/viewtopic.php?t=505597)
- Outfront Motorsport adapter plate & 228mm flywheel (Kennedy style)
- Rocky Mountain Westy Hi-Torque Starter Adapter
- 1996-2003 Bosch/VW SR0408X/409X MT TDI starter
- Rocky Mountain Westy bolt-on (no cut) Engine Carrier Bar
+HIDDEN UNTIL LAUNCH+ Throttle Valve Reverser
- Tom Shiel's Concept 5 Aluminum thermostat housing
- Rocky Mountain Westy SS Exhaust Header & exhaust mounting w/OBD2
+HIDDEN UNTIL LAUNCH+ Heat Shield
Magnaflow Catalytic Converter w/OBD2 P/N 53034
Walker SoundFX Muffler P/N 17837
Donaldson PowerCore Air Filter P/N D080020[/u]
Thanks to Skills, JMSkater, Mild-Core, 55Beetle, and several others for sharing and encouragement. I just need my Christmas check to show up and I'll be back working away at it. To date, the engine is sourced, pulled and cleaned up, and the donor vehicle has been stripped of its wiring harness. (An all day affair.) Present work is mostly muscle, including replacing the battery tray and preparing (with documentation) the VW harness to interface with the Subaru harness.
Marshall