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Re: Vanagon with a DOHC 2.5 engine in North or South Carolina.

Scott Daniel - Turbovans #62986 Hi... not sure if I want to do a video chat.. I welcome your questions .. and send digital pics . here is how I suggest to proceed. On the physical end of things.. get engine and trans mounted in the van. then get it cranking on the starter. at the very first oportunity .....test clutch operation ..that the pedal is obviously pushing on something ... like there is resistance ..and it 'feels right'. ( I have seen people work on an engine installation for many many hours .. only to find out when they go to start it , the clutch is messed up somehow ...so test clutch for proper feel at the very first opportunity. on the wiring harness .. I have had to straighten out poorly done ones a few times, and on one DOCH 2.5 ....everything was 'chopped' ..harness chopped of a foot from the engine, a foot from the ecu, etc. I had to fill in every last wire and coax ...but it came out great. I just 'start at pin 1 on the ecu, and keep going.' Make a list as you go ...........pin 1 say .....black/red small wire............goes to such-and-such. Continuity check each wire 3 times. if using wire splices, pull-test each one, and cover them with shrinkable tubing. what is really smart ..while you're buidking or checking the harness ...is have the main harness connected to the engine .. so when you identify and check say injector # 3 .......you continuity check all the way from the ecu connector through the engine plugs to the device on the engine. And check it 3 times. I have seen the engine plugs not make connection before ... so I always run temp sender for the dash gauge and oil pressure on dedicated wires from sensor on engine to vanagon wiring. some of my other tips ... I am extremely big on don't do anything except the very minimum to fire it up ...to confirm that the wiring harness work is good. Don't wire in anything about a tach , for examle. don't wrap the harness. don't install the ecu under the back seat.. just lay the whole thing out next to the engine for your first time to fire it up. that way ...if something isn't right ..you don't have to unwrap the harness to fix it .. you don't have to pull it back out of the van to check and fix it etc. then when you know it can fire off and idle.. then start wrapping and installing the harness and ecu. when you know it starts, idles, and runs right ..then fuss with embellishments like tach. try to do everything as carefully as you can .. so when you do go to start it up .. you get that ole 'click-VROOOM ! ' ....on the first try. That's a super good feeling. I suspect there are a lot of started but never finished conversions out there. nice to see your post, Scott www.turbovans.com toggle quoted message Show quoted text On 3/5/2012 1:35 PM, James Henry wrote: Darrel, I am another NC vanagon owner with a 2.5 (96) that is incomplete and could use some input. I think I have most of mine figured out, except for wiring. My wiring harness was done a shop in Raleigh, but never installed, not really finished. I have finally found the time and courage to get into it and figure it out. I am hoping to put it in the vanagon this weekend if I can get answers to a couple of questions. Brent, your site has been enormously helpful. I have most of the other parts figured out. I think. Brent or Scott, or anyone else, I could do a video chat through FaceBook, or Microsoft Messenger, or WebX from my laptop and interactively ask a couple of questions, if you would be up for it. You would not need video at your end, we could talk via telephone. A laptop in the shop is a wonderful thing. I have a reverse cooling system from Tom Shields, and a lot of SmallCar parts. This project has been going on for too many years, Tom has been very helpful, as has SmallCar. Darrel, I am not that far from Charlotte, maybe we could collaborate. I could even come to Charlotte. Did you buy your project from a hotrod shop south of Raleigh? You beat me to it if you did. I am in Durham. Thanks to all for any and all help. I hope that I have not jumped your thread here Darrel, sounds like we are sharing some common problems and are working to the same end. We need to have these done and ready to show off at EveryBus in April!!!!! www.everybus2012.com Jim Henry Durham, NC 84 Westy _____ From: subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com> [mailto:subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com>] On Behalf Of DARREL Sent: Sunday, March 04, 2012 21:42 To: subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com> Subject: [subaruvanagon] Vanagon with a DOHC 2.5 engine in North or South Carolina. I am trying to complete the installation of a 99 2.5 DOHC engine in an 86 Vanagon Weekender. I bought this vehicle from a third party seller, who had very little information about the vehicle, other than that the engine was from a 99 Legacy with 44,000 miles, and that he heard it run before it was removed from the Subaru. I talked to small car, and from my description, they said it did not sound like the modification parts were from them. The seller did say that he possibly remembered that the owner mentioned getting a modification kit from a Subaruvanagon member named Bryan, spelled with a Y instead of an I. The installation appears to be about 80-85% complete, but there are still some areas that have me at a loss. If I could have the opportunity to look at a completed installation, I think it would give me enough information to get this project wrapped up in time for camping season. SO - I'm wondering if anyone within a 2-3 hour drive of Charlotte, NC would have a V-gon with a 2.5 DOHC that I could come and inspect, and maybe make a few photos of the areas I have questions about, so I can get this vehicle on the road. Thanks in advance! Darrel

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