Re: Warren¡¯s Conversion - Update #1
Do you have the fuel line dampers (black valve looking thingys)? I had one that I installed on the return line. On some pics I see there are two. I don't know how critical they are.
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Re: Warren¡¯s Conversion - Update #1
Got the CV axles reattached and torqued to 33 ft lbs.
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In this photo you can see the routing of the fuel-in and fuel return lines as well as the evap line. ?Also to the right is the RMW expansion tank installed and wired up. ?On the left is the brake booster line that I still need to connect. ?Another update soon!
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Warren
89 Westy?
88 Tintop
70 Westy
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Re: Warren¡¯s Conversion - Update #1
I got the alternator and AC compressor mounted, belts tightened, and installed the covers. ?I was able to start connecting the wiring harness as well. ?Here you can see the alternator and AC compressor connected.?
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I then crawled back under and got the starter wired up. I¡¯m using one of the high torque starters with the Westy Ventures adapter.
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While I was under there I reattached the shifter linkage. ?Yes, I should have replaced all of the boots but I decided to leave that for another day.
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I fed new fuel and return lines through the firewall. ?As well as the evap line (and the wiring to the coolant level sensor).
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Here you can see the new fuel lines attached to the rigid plastic fuel and return hoses.
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Not a lot of fun, but I was able to reattach the clutch slave cylinder. ?Note to self: if the transmission is ever out again, take the time to spot weld that rear-most bolt into place. ?That would have been so easy with the transmission out, but now without the bolt in place it¡¯s a known struggle to get it installed. ?
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Warren
89 Westy?
88 Tintop
70 Westy
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Re: Warren¡¯s Conversion - Update #1
I used my engine hoist to raise it into position so that I could attach the RMW engine mount. ?
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Working alone I had a heck of a time getting that support installed. ?Up to this point I have done all the work myself from pulling the engine, building it, joining the engine and transmission, rolling it into place and lifting it. ?But installing the crossmember almost made me call for help because of its shape and because it is heavy and awkward to handle. ?Instead, I sat down and thought about another way. ?So I built a cradle and used the motorcycle jack to lift it up from the center. ?It was still a struggle to get everything lined up, but it worked. ?And drilling those extra holes in the frame was not a fun time. ?Metal filings in the face. ?Not good.
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But finally, there it was, bolted into place. ?If you¡¯re using the RMW kit, you will need to install those spacer bolts to the timing belt cover, but do not put the heat shield on just yet. ?If you do, like I did, you will have to take it back off in order to install your alternator and AC belts. ?In this photo my alternator is in position and the AC belt sorta in position.
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Next, I started connecting all the coolant hoses. ?That whole passenger side is crowded with those stainless coolant pipes and heater hoses going here and there.
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I finally got around to connecting the stainless coolant pipe from the thermostat.
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You¡¯re supposed to use this brace for the t-stat coolant pipe, but I could not get it installed as suggested by the RMW instructions. ?
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So I created my own brace out of pipe hanger material. ?
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Warren
89 Westy?
88 Tintop
70 Westy
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Warren¡¯s Conversion - Update #1
It¡¯s been a while since I¡¯ve updated my conversion progress, so here goes. ?
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Jacked the bus as high as it would go and rolled the engine and transmission into place. ?The real challenge was keeping the transmission jack from twisting about. ?
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I looked down and suddenly there it was, ready to lift into position.?
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I used the motorcycle jack and transmission jack to slowly lift it into position by alternately lifting the motorcycle jack then the tranny jack, back and forth until it I could connect the transmission.
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I finally got the transmission mounted and slid it as far forward as it would go. ?I¡¯ve tightened the bolts but I¡¯m not sure what the torque specs are for them.?
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Warren
89 Westy?
88 Tintop
70 Westy
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Re: '91 Westie with '07 Forester 2.5
Terry, I'd like to connect with you at BusFusion to compare our conversions. I'm trying to figure out just which engine I have and it may be the same as yours, in our 85. We'll likely be parked near the ag hall end; ask around as lots of people know us, and I'll try to find you too. Cheers,? Jim Wallace?
On Mon, May 19, 2025, 9:27 p.m. Noras dad via <norasonlydad= [email protected]> wrote: Yo Joel,? Glad to see you got this prob figured out. Let me know when you are headed up to Labrador/ Newfoundland please. We are heading on that journey directly after BUSfusion in Almonte Ontario. Would be great to sup on a pop somewhere along the route.? 85 Westy ( Winston)with 2002 N/A 2.5 Subie with Tod's reverse ring and pinion installed in his 5 speed tranny. Terry
Hello all, Hoping someone may have an idea, been working on this for a few days with little success, and of course we are supposed to be heading out for a 6 week trip across Labrador & Newfoundland.
Had the conversion done a year ago, everything was fantastic for last year's 12,000 km trip to the west coast of BC. (Should have done the conversion year's ago)
Couple days ago was heading to the garage for a minor upgrade, when things started to 'turn off', until the van was barely able to run, battery down to ~7V.? I have a battery switch to flip between vehicle and house battery, enabling me to go the additional distance.
We have tried 4 different alternators, with the engine running all of them max 12.4 V.? Have unplugged the alternator cables so no load, still only about 12.4V.? Take them out of my van, install in another, and they go up to around 14.4V.??
Belt seems ok, cam shaft pulley also ok.
Do one of the 3 connectors on the one plug of the alternator provide some kind of V sensing where if it isn't connected or loose/corroded, so max the alternator puts out is around 12.4V?? If yes, where is the other end of that going?
Any other ideas or thoughts are much appreciated.
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Agreed.? Jake
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Crescent Beach, BC
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1984 GL 1.9 WBX
1986 Westy Weekender with 2000 2.5 SOHC Subaru, 5 speed transaxle & PosiTrac Differential
On Mon, May 19, 2025 at 6:40?PM Noras dad via <norasonlydad= [email protected]> wrote: I just need to say;? Wayne you are the best, always so much factual information and so damn helpful. Even if I've never had a problem that is being described, I'm always so impressed by your solid and informative reply. Thanks so very much for you, and your knowledge and your willingness to share. You make this world a much better place. Cheers. Terry?
You need ignition start signal to the ECU which I did to the VW wire in the black box and you need it to go the solenoid on the starter. I connected in the black box and used the VW start wire to the solenoid.
On my 02 2.5L? harness, the wire going to the ECU had a bigger gauge double splice coming off it, I think one would go to ignition Switch and the other to the starter solenoid.
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I just need to say;? Wayne you are the best, always so much factual information and so damn helpful. Even if I've never had a problem that is being described, I'm always so impressed by your solid and informative reply. Thanks so very much for you, and your knowledge and your willingness to share. You make this world a much better place. Cheers. Terry?
You need ignition start signal to the ECU which I did to the VW wire in the black box and you need it to go the solenoid on the starter. I connected in the black box and used the VW start wire to the solenoid.
On my 02 2.5L? harness, the wire going to the ECU had a bigger gauge double splice coming off it, I think one would go to ignition Switch and the other to the starter solenoid.
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Re: '91 Westie with '07 Forester 2.5
Yo Joel,? Glad to see you got this prob figured out. Let me know when you are headed up to Labrador/ Newfoundland please. We are heading on that journey directly after BUSfusion in Almonte Ontario. Would be great to sup on a pop somewhere along the route.? 85 Westy ( Winston)with 2002 N/A 2.5 Subie with Tod's reverse ring and pinion installed in his 5 speed tranny. Terry
Hello all, Hoping someone may have an idea, been working on this for a few days with little success, and of course we are supposed to be heading out for a 6 week trip across Labrador & Newfoundland.
Had the conversion done a year ago, everything was fantastic for last year's 12,000 km trip to the west coast of BC. (Should have done the conversion year's ago)
Couple days ago was heading to the garage for a minor upgrade, when things started to 'turn off', until the van was barely able to run, battery down to ~7V.? I have a battery switch to flip between vehicle and house battery, enabling me to go the additional distance.
We have tried 4 different alternators, with the engine running all of them max 12.4 V.? Have unplugged the alternator cables so no load, still only about 12.4V.? Take them out of my van, install in another, and they go up to around 14.4V.??
Belt seems ok, cam shaft pulley also ok.
Do one of the 3 connectors on the one plug of the alternator provide some kind of V sensing where if it isn't connected or loose/corroded, so max the alternator puts out is around 12.4V?? If yes, where is the other end of that going?
Any other ideas or thoughts are much appreciated.
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Looking at this connection on B135: (2000 Legacy file chart)
b28 WL Inhibitor Sw Conn. to b26 & Van Ign T7a6(RB)
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Connecting the start signal to the neutral switch on an AT van - does it do anything? You get continuous low voltage to your brake light on the dash. I've seen this on my van and diagnosed it on another van as well.? For MT van should be grounded. For AT van can be disconnected or grounded. Any info?
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We do have the RMW manual (not impressed by the way lol) and now the Small Car (thanks for that) as well as these lovely diagrams you all sent!! Printing them off and going to get started! My husband is working on coolant lines today. Just wiring, throttle cable, fluids, fuel lines, ecu mounting, and odds and ends left!!?
Nick Clinton-Elliott (He/Him/His)
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On May 18, 2025, at 11:34?AM, Nicholas Clinton <nlc646s@...> wrote:
? Nick Clinton-Elliott (He/Him/His)
Begin forwarded message:
From: "Nicholas Clinton via groups.io" <Nlc646s@...> Date: May 17, 2025 at 2:57:18?PM CDT To: [email protected], Steven Clinton-Elliott ICE <grs.elliott@...> Subject: [SubaruVanagon] Into to Clinton ClanReply-To: [email protected]
? Hello, I have been following silently for awhile now, but thought I should pipe up and introduce myself, my husband and our VWs! I am Nick and my husband and I have an 87 Vanagon weekender named Lucille (loose seal). She has 304,000 miles on her. We drove from Missouri to LA a couple months ago to pick her up and trailer her home. Got her for a great deal with bad waterboxer head gasket. Long story short two weeks later we are driving to Arkansas to pick up an ¡®82 Westie that came with almost enough conversion parts (including EJ25 with 30K miles) to convert Lucille and one of our other vans, plus loads and loads more new parts. I had the ENTIRE Vanagon full of parts PLUS we also filled the whole back of our Honda Pilot with parts. The previous owner had purchased a Rocky Mountain Westy (now part of Van Cafe I think) adapter plate/conversion kit and then he decided to change routes and do the SubaruGears kit reverse Ring and pinion setup complete with a subi 5spd. Anyway, I could ramble on forever about our four busses, but to the point lol. ? One thing that we did not have is an ECU/Wiring, so we went to our pick n pull and got the ¡®01 Subaru Legacy wiring and ECU. I have it stripped and all dead plugs removed. When I started this I couldn¡¯t find anyone that does the drive-by- cable harness (I have since discovered Jeff with Autoventures(?)). I have ECU pins printed and ready to guide me as well as a Vanagon Bentley manual. I have done several engine swaps over the years years, just none on a Vanagon and wiring has ALWAYS been my biggest challenge! Thankfully this isn¡¯t an ALH TDI, that was ROUGH! Lol! Any tips/advice before I start soldering? Any good write-ups or videos anyone would recommend?Nick Clinton-Elliott (He/Him/His       
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Busaroo actually did my harness conversion for my 2.5 2005 outback Subie?engine. Fantastic job. The 2005 vehicle was a transition car between 2004 and 2006 and was a cross between the two types and as such posed particular?problems, but Busaroo?sorted it out and got me up and running. So glad I went that route.?
Here are someone's colour coded pinouts while asking a question about a few wires,that I had on file. They might be of some help.
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From wiring hell in the files. (2000-2002 are all the same) /g/SubaruVanagon/files/Wiring/WIRING%20DIAGRAMS/ECU%20WireList2000-2.5sohc.pdf
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Busaru on YouTube has excellent videos on conversion wiring.
On Saturday, May 17, 2025 at 12:57:21 PM PDT, Nicholas Clinton via groups.io <nlc646s@...> wrote:
Hello,
I have been following silently for awhile now, but thought I should pipe up and introduce myself, my husband and our VWs! I am Nick and my husband and I have an 87 Vanagon weekender named Lucille (loose seal). She has 304,000 miles on her. We drove from Missouri to LA a couple months ago to pick her up and trailer her home. Got her for a great deal with bad waterboxer head gasket. Long story short two weeks later we are driving to Arkansas to pick up an ¡®82 Westie that came with almost enough conversion parts (including EJ25 with 30K miles) to convert Lucille and one of our other vans, plus loads and loads more new parts. I had the ENTIRE Vanagon full of parts PLUS we also filled the whole back of our Honda Pilot with parts.
The previous owner had purchased a Rocky Mountain Westy (now part of Van Cafe I think) adapter plate/conversion kit and then he decided to change routes and do the SubaruGears kit reverse Ring and pinion setup complete with a subi 5spd.
Anyway, I could ramble on forever about our four busses, but to the point lol. ? One thing that we did not have is an ECU/Wiring, so we went to our pick n pull and got the ¡®01 Subaru Legacy wiring and ECU. I have it stripped and all dead plugs removed. When I started this I couldn¡¯t find anyone that does the drive-by- cable harness (I have since discovered Jeff with Autoventures(?)). I have ECU pins printed and ready to guide me as well as a Vanagon Bentley manual. I have done several engine swaps over the years years, just none on a Vanagon and wiring has ALWAYS been my biggest challenge! Thankfully this isn¡¯t an ALH TDI, that was ROUGH! Lol! Any tips/advice before I start soldering? Any good write-ups or videos anyone would recommend?
Nick Clinton-Elliott (He/Him/His
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The RMW conversion kit comes with a step-by-step manual. Do? you have it? Busaru.com has several Youtube videos on wiring. He shows a 2001 as I recall. The set of installation pages at Smallcar.com have a write-up and photo of the main harness to vanagon wiring connections (about half-way thru).? Look at the files and photos on this site. There are full conversion threads on theSamba.
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Hello,
I have been following silently for awhile now, but thought I should pipe up and introduce myself, my husband and our VWs! I am Nick and my husband and I have an 87 Vanagon weekender named Lucille (loose seal). She has 304,000 miles on her. We drove from Missouri to LA a couple months ago to pick her up and trailer her home. Got her for a great deal with bad waterboxer head gasket. Long story short two weeks later we are driving to Arkansas to pick up an ¡®82 Westie that came with almost enough conversion parts (including EJ25 with 30K miles) to convert Lucille and one of our other vans, plus loads and loads more new parts. I had the ENTIRE Vanagon full of parts PLUS we also filled the whole back of our Honda Pilot with parts.
The previous owner had purchased a Rocky Mountain Westy (now part of Van Cafe I think) adapter plate/conversion kit and then he decided to change routes and do the SubaruGears kit reverse Ring and pinion setup complete with a subi 5spd.
Anyway, I could ramble on forever about our four busses, but to the point lol. ? One thing that we did not have is an ECU/Wiring, so we went to our pick n pull and got the ¡®01 Subaru Legacy wiring and ECU. I have it stripped and all dead plugs removed. When I started this I couldn¡¯t find anyone that does the drive-by- cable harness (I have since discovered Jeff with Autoventures(?)). I have ECU pins printed and ready to guide me as well as a Vanagon Bentley manual. I have done several engine swaps over the years years, just none on a Vanagon and wiring has ALWAYS been my biggest challenge! Thankfully this isn¡¯t an ALH TDI, that was ROUGH! Lol! Any tips/advice before I start soldering? Any good write-ups or videos anyone would recommend?
Nick Clinton-Elliott (He/Him/His
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Re: '91 Westie with '07 Forester 2.5
Good old alt light. Glad you got it fixed.?
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Re: '91 Westie with '07 Forester 2.5
Thanks much to everyone, Problem resolved.
About a month ago I had removed the instrument cluster to fix the odometer (little white gear had come off, didn't stay on long) and when I reinstalled it, seems I scrunched one pin on the connector to the blue foil circuit.? There must have been just enough contact for the alt light to still come on, although maybe slightly dimmer.? Not sure if it was shorting out but after replacing the pin, alternator is now in the 14.5 V range.?
One item we hadn't thought of, I have a complete solar system installed, along with a Renogy MPPT Battery Charger/Solar Controller.? They are great units, but with the ability of charging both house and starter batteries from solar, our thinking is the starter battery was always charged because of the solar setup.? Short trips never drained the starter battery enough to notice any difference.? It wasn't till I drove about an hour that things started failing.
Try searching theSamba forum threads with something like Subaru alternator low voltage. Here's one: ?
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Re: '91 Westie with '07 Forester 2.5
Try searching theSamba forum threads with something like Subaru alternator low voltage. Here's one: ?https://www.thesamba.com/vw/forum/viewtopic.php?t=744842&highlight=subaru+low+voltage+alternator
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Re: '91 Westie with '07 Forester 2.5
Blue /red sense wire goes to the battery post on alternator or to battery post on starter or to + post on battery (with 10 amp fuse like Subaru has it)
TRy running a ground wire to the alternator bracket. Maybe? your engine grounds (intake to frame or trans to frame) are inadequate.
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