Re: Warren¡¯s Conversion - Update #1
I guess this is what I had in the return line.?
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https://www.subaruoutback.org/threads/fuel-pulsation-damper-how-its-constructed-and-works-and-issues-symptoms-etc.514134/
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Re: Warren¡¯s Conversion - Update #1
This evening I loosely fitted the throttle cable. ?
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Then I used some 10mm silicone vacuum line to connect the brake booster line to the passenger side intake manifold. ?Some folks, I understand, are fortunate enough to be able to connect the booster to a port on the driver¡¯s side.
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I routed it under the intake and out the other side. ?I¡¯ll wait to clamp it permanently once other things are sorted on the passenger side of the engine. ?There¡¯s lot of stuff going on there.
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Warren
89 Westy?
88 Tintop
70 Westy
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Re: Warren¡¯s Conversion - Update #1
I had this Glow Shift oil pressure gauge on my 2.1. ?
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It uses a sandwich adapter between the oil filter and the block. ?I¡¯ve ordered the adapter to make it work (hopefully) on my 2.5.
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Warren
89 Westy?
88 Tintop
70 Westy
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Re: Warren¡¯s Conversion - Update #1
I found some by Evil Energy on Amazon. ?
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They come in different sizes. ?I¡¯ve never used one of these.
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Warren
89 Westy?
88 Tintop
70 Westy
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Where did you get your new aluminum expansion tank? ?Either it had a sensor mounted or a place for one.?
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Warren
89 Westy?
88 Tintop
70 Westy
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Yes, there was a factory coolant level sensor that screwed into the top of the original 2.1 expansion tank. It had two prongs. When you started the 2.1 engine the temp light flashed a few times then, if there was coolant enough to touch the contacts, it went out.?   --
Warren
89 Westy?
88 Tintop
70 Westy
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So wait, there was a factory coolant level sensor? How did it work? How did you know it went off? My Vanagon was converted in 2002 and I didn¡¯t own it until?10 years after that so no surprise I didn¡¯t know about this.?
The coolant expansion tank from RMW includes a coolant level sensor.
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But they also sell just the replacement sensor for about $15
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Warren
89 Westy?
88 Tintop
70 Westy
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The coolant expansion tank from RMW includes a coolant level sensor.
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But they also sell just the replacement sensor for about $15
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Warren
89 Westy?
88 Tintop
70 Westy
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Re: Warren¡¯s Conversion - Update #1
I have not installed any fuel line dampers. ?To my knowledge there were none on the 2.1 setup, so there are none on my 2.5 installation. ?Are they critical? ?Do you know where they can be purchased?
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Warren
89 Westy?
88 Tintop
70 Westy
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I just caught a mention of a coolant level sensor in Warren¡¯s emails regarding his install. I enjoyed his pics and write up very much. When I get through my current failed head gasket situation I want to add a coolant level sensor. My expansion tank cracked on the freeway and I lost the gasket. I¡¯ve since installed a new aluminum expansion tank but the damage was already done. What are you all doing for coolant level sensors? Where¡¯d you get them? What parts did you buy? Where did you install them? How did you install them??I¡¯m actually open to some kind of horn situation but want to hear what you¡¯ve done.?
Back in my salt flats days we put a massive horn on our racers coolant level sensor so you could hear it over a 736 cubic inch diesel engine with a helmet on.?
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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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