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I thought as I move to phase two of this project it would make sense to start a new topic related to pulling the engine and transmission from my 89 Westy.?  Hang with me as I’ll need some advice going forward ?Thanks!
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Warren
89 Westy?
88 Tintop
70 Westy
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Okay, so I’ve started on the removal of the 2.1 from my Vanagon to make way for the Subie 2.5.
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Here’s a photo of a perfectly good running 2.1 that I have driven coast to coast several times. ?The most recent trip was to Buses by the Bridge in Lake Havasu City, AZ. (About 700 buses there - way too many for me - been there, done that, don’t think I want to do it again).
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Warren
89 Westy?
88 Tintop
70 Westy
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I pulled the bus into my garage and, mustering courage, started prepping it for the removal. ?I began by using my shop vac to suck all the coolant out of the system by vacuuming through the coolant reservoir. ?I first opened the bleeder valve at the radiator to allow air to come in from the front. ?I vacuumed for a while, allowed things to settle, then vacuumed again and again. ?Eventually the system was bone dry.
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Warren
89 Westy?
88 Tintop
70 Westy
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Because I intend to remove the gas tank to install stainless coolant pipes and to do maintenance on the tank lines, I drove it around until it was way below the empty mark. ?I carried a gallon of gas with me just in case I ran out and had to put a little in to get home. ?But I made it home safely. ?Then I removed the 7mm screw on the fuel “T” and attached a few feet of fuel line to it. ?I pulled the cover off to access the relay (Number 53) and used a jumper to cause the fuel pump to run, thus emptying the tank and all the lines. ?It worked very well.
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Warren
89 Westy?
88 Tintop
70 Westy
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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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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
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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
|
You could always leave the intake manifold off the Subie for the install.
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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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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
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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
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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
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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
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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
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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
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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
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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
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Wow. Good job !
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Warren
89 Westy?
88 Tintop
70 Westy
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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
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