Re: Warren’s Conversion - Removing VW Wiring Harness
Thanks Wayne. ?I’m going to get started on it today and I’ll pull the ECU and work backwards the way you suggest. ?I’ll post an update later today (these postings keep me motivated!). Last night I was looking at 2.1 prices and they’re pretty high! ?I also saw a 2.1 ECU alone that was for sale for $400 I think. ?So I will sell the ECU and wiring harness separate from the engine. ?
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Warren
89 Westy?
88 Tintop
70 Westy
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Re: Warren’s Conversion - Removing VW Wiring Harness
The whole harness comes out intact. I would start at the ECU and work to the engine compartment. I would sell it separately for more $.?
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Re: Warren’s Conversion - Removing VW Wiring Harness
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - Removing VW Wiring Harness
Well, I did nothing with the wiring harness today. It was a very warm and nice day here so I opted to spend some time cleaning 36 years of grime from the transmission. A bit more work on it tomorrow and I’ll start on the wiring.  --
Warren
89 Westy?
88 Tintop
70 Westy
|
Warren’s Conversion - Removing VW Wiring Harness
Today I thought I would begin removing the Vanagon wiring harness and ECU, but I have no clue how to go about this, I.e., what to remove and what to leave behind. Since I’ve decided to sell the 2.1 I would like to remove the harness without cutting any wiring if possible and let it go to whoever buys the engine.?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
So all I accomplished today was to split the engine and tranny and remove the starter. I needed an easy day!  --
Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
Wow. Good job !
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
Some pictures of where I started?
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On Mon, Feb 24, 2025 at 6:28?AM John <xstreamcanadian@...> wrote:
Yes total rebuild. New regulator, new brushes, new bearings both ends. I have the same feeling wondering if it’s going to work lol. A local guy will bench test for 10 bucks so I may do that when done. Everything about it is a hassle. ?Made one out of two had to get one from the pick and pull as the screws holding the regulator were rusted out on mine as were the ones on the cover holding in the front bearing plate.? On Sun, Feb 23, 2025 at 4:14?PM SubieVanagon via groups.io <wklail@...> wrote:
John, are you rebuilding the Subaru alternator? ?I took mine apart to clean and inspect the brushes. ?What a job. ?Getting that screw out way in the back was a nightmare. Then putting it back together wasn’t easy either. ?I hope mine works when I fire up the Subaru engine! ?There’s a trick to getting it back together where the brushes are an issue. ?You use a very small allen wrench and stick it in the tiny hole at the back, then press the brushes in and they will stay there until you pull the allen wrench back out. ?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
I need to get mine bench tested as well. ?It will be worth it to know whether it is going to work prior to installing it. ?The heads snapped on two of the machine screws when I was taking the cover apart, so I used an easy-out to remove them and used new stainless steel screws when I put it back together. ?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
Yes total rebuild. New regulator, new brushes, new bearings both ends. I have the same feeling wondering if it’s going to work lol. A local guy will bench test for 10 bucks so I may do that when done. Everything about it is a hassle. ?Made one out of two had to get one from the pick and pull as the screws holding the regulator were rusted out on mine as were the ones on the cover holding in the front bearing plate.?
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On Sun, Feb 23, 2025 at 4:14?PM SubieVanagon via groups.io <wklail@...> wrote:
John, are you rebuilding the Subaru alternator? ?I took mine apart to clean and inspect the brushes. ?What a job. ?Getting that screw out way in the back was a nightmare. Then putting it back together wasn’t easy either. ?I hope mine works when I fire up the Subaru engine! ?There’s a trick to getting it back together where the brushes are an issue. ?You use a very small allen wrench and stick it in the tiny hole at the back, then press the brushes in and they will stay there until you pull the allen wrench back out. ?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
John, are you rebuilding the Subaru alternator? ?I took mine apart to clean and inspect the brushes. ?What a job. ?Getting that screw out way in the back was a nightmare. Then putting it back together wasn’t easy either. ?I hope mine works when I fire up the Subaru engine! ?There’s a trick to getting it back together where the brushes are an issue. ?You use a very small allen wrench and stick it in the tiny hole at the back, then press the brushes in and they will stay there until you pull the allen wrench back out. ?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
As expected the cv axles got caught repeatedly on the transmission, so I would lower, raise, wriggle, and do it over and over again until they cleared. ?But it’s out and in my driveway. ?I’ll probably separate the engine and transmission tomorrow. ?I am reconsidering my plan to keep the 2.1. ?I’m convinced that I will find another 2.5 subie for my 88 tintop, so selling the 2.1 makes more sense. ?Someone contacted me last night and asked, but last night I was convinced I would keep it. ?But now I’ll list it on the samba once I figure out a fair price. It has 207,000 miles on it but runs great so I’m thinking someone must have had it rebuilt at some point. ?Does not even use oil. ?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
So today was the day! ?I chose to pull the engine and transmission together. ?I’m not sure that was wise. ?It didn’t seem much easier and was heavier to pull it out. ?It was a bit much for one man working alone. ?Hopefully my Advil will kick in soon!
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
Great photos and write up so far Warren thanks. I have a motorcycle jack too but I’m planning on using a lower profile appliance dolly under both the trans and motor. Sits quite a bit lower. If you’re short on room I’d try that rather than install the intake later as to me there is inherent risk with that or at least it’s a hell of a lot easier on a stand to drop the intake in place and make the many associated connections?
Keep up the momentum! It’s inspiring me for sure. I’m rebuilding my alternator at the moment which is proving to be somewhat regrettable?
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On Sun, Feb 23, 2025 at 5:32?AM SubieVanagon via groups.io <wklail@...> wrote:
Good point. However I have an 88 tintop automatic that I plan to make my townie bus so I might need the 2.1 for it (unless I come across another 2.5 sometime soon).?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
Good point. However I have an 88 tintop automatic that I plan to make my townie bus so I might need the 2.1 for it (unless I come across another 2.5 sometime soon).?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
List the engine, harness ECU etc on theSamba for an outrageous price. Pepople still want that 2.1, 95 hp stuff.
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Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
You could always leave the intake manifold off the Subie for the install.
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Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
As you can see, I don’t have much room up top because my garage ceiling is only 8ft. ?But I’m confident it will work. ?I need the rear “valance” of the bus to be 28 inches above the floor in order for me to roll the Subie engine in place on its motorcycle jack. ?Right now I have 24 inches of clearance, which should be enough to get the 2.1 and transmission out together. ?But before I try to install the Subie engine I will have to jack it up once again even higher. ?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
I drained the oil as well. ?So after working everything from the top side, I jacked it up and put stands under each rear tire (front tires chocked). ?Tomorrow I plan to disconnect the CV axles, shifter linkage, and anything else I see under there that needs to be disconnected before I go any farther. ?
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Warren
89 Westy?
88 Tintop
70 Westy
|
Re: Warren’s Conversion - 2.1 Engine and Tranny Removal
So today I began work in earnest disconnecting everything that would need to be removed in order to lower the engine out. ?This included the power steering lines, vacuum hoses, coolant lines from the thermostat housing and reservoir and those lines that attach to the plastic coolant rail that runs around the perimeter of the engine. ?I also disconnected the wires to everything that would otherwise prevent me from lowering the engine, including the O2 sensor wire. ?I also disconnected the throttle cable and the throttle cable bracket that attaches to the transmission. ?I was also able to disconnect the clutch slave cylinder from the engine side, which was nice. ?I wanted to do as much as possible from up top (I really don’t like lying on my back under a bus). ?The AC compressor has been dead for a long time and thankfully was not charged. ?I was able to pull the dipstick tube out of the block, but not the oil filler tube (does anyone know how to get it off, or does it even need to come off in order to lower the engine?). ?
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Warren
89 Westy?
88 Tintop
70 Westy
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