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Vanagon with a DOHC 2.5 engine in North or South Carolina.
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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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Scott Daniel - Turbovans
Hi,
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I can send you pictures of such an installation. Just finished one recently. what particular areas do you have questions about .. mechanical stuff...say engine mounting , exhaust etc. ? or electrical...as in wiring harness . ? and interfacing the subaru electrical part with the vanagon electrical part ? Scott www.turbovans.com On 3/4/2012 6:41 PM, DARREL wrote:
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Morning Darrel.
I'm pretty familiar with the 99 phase 1 ej25. If you post some pics of parts that you're trying to identify i (and others on the forum) will likely be able to help you with identifying them. Let us know what areas of information you are looking for as related to wrapping up your project. We should be able to get you through it just fine. Thanks, Brent -- Brent Weide Portland, Oregon www.weidefamily.net/vanagon/ |
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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@...] On Behalf Of DARREL Sent: Sunday, March 04, 2012 21:42 To: subaruvanagon@... 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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Scott Daniel - Turbovans
Hi...
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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 On 3/5/2012 1:35 PM, James Henry wrote:
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Thanks Kent, Brent, James, and Scott?for your timely response. It does appear, however that James and I have one common connection, however. Yes, James, this is the vehicle that was at the Hot Rod shop near Raleigh. The shop owner said that he thought that the wiring harness was sent to someone in Chapel Hill to be modified, but I'd be willing to bet that it was done by the same person in Raleigh thad did yours. Much of the wiring has been installed, but there are still a number of wires, almost all without connectors on the ends,?that need to find a home. The wires?had all been?tagged with paper tags indicating where they went, but after sitting outside for a couple of years, the printing on almost every tag has faded to the point that it is illegible. One big question that I have is concerning 3 relays that are part of my harness. These are 3 identical relays that are mounted together on?the left side of the engine compartment. There are wires
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coming from the harness bundle that attach to the relays, and then there are wire pigtails about 10" long?that come from the relays and are hanging loose. With time, I think I could trace out the rest of the wires, to determine where they go, but since the relays are not factory Subaru, I can't even guess what their purpose might be, or where the pigtails should be attached. Do you know, by chance, the name of the shop that did your harness modification? If they are still in business, maybe we could get a little assistance from them. In the meantime, I thought I'd try to make some photos of the different areas I have questions about in the next few days, and post them for inspection by any helpful group members. Thanks again, everyone for your assistance !! --- On Mon, 3/5/12, James Henry <jch@...> wrote:
From: James Henry <jch@...> Subject: RE: [subaruvanagon] Vanagon with a DOHC 2.5 engine in North or South Carolina. To: subaruvanagon@... Date: Monday, March 5, 2012, 4:35 PM 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@...] On Behalf Of DARREL Sent: Sunday, March 04, 2012 21:42 To: subaruvanagon@... 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 ------------------------------------ Yahoo! Groups Links [Non-text portions of this message have been removed] |
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Hey James,
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Once you get your conversion completely, please note the '96 EJ25d is a one off year with higher compression and requires premium gas. Just wanted to let you know. I had a friend with that same engine, he didn't know it required 91 octane and blew it up on the freeway, not sure if the fuel had anything to do with it, but he said he sure wished he new it is suppose to run on premium! Paul --- In subaruvanagon@..., "James Henry" <jch@...> wrote:
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Paul - Did I read understand your post correctly that the '96 2.5 engine was the only one that needed premium fuel, and that I?should be able to?use 87 octane in my?'99 2.5 when I finally get it on the road?
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--- On Thu, 3/8/12, gouldp48 <gouldp48@...> wrote:
From: gouldp48 <gouldp48@...> Subject: [subaruvanagon] Re: Vanagon with a DOHC 2.5 engine in North or South Carolina. To: subaruvanagon@... Date: Thursday, March 8, 2012, 10:39 PM Hey James, Once you get your conversion completely, please note the '96 EJ25d is a one off year with higher compression and requires premium gas.? Just wanted to let you know.? I had a friend with that same engine, he didn't know it required 91 octane and blew it up on the freeway, not sure if the fuel had anything to do with it, but he said he sure wished he new it is suppose to run on premium! Paul --- In subaruvanagon@..., "James Henry" <jch@...> wrote:
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Yes, I beilve that is correct. The 96 2.5 had one year only dished
piston that raised the compression quite a bit and therefor required 91 octane. I don't think any other year NA 2.5's required premium gas. Interested too, since the 96 was only rated at 155 hp and the rest of the EJ25d's were rated at 165. You would think with the higher compression came more power. The later pistons had short skirts whiched produced more power but were subjected too more piston slap. I might be worth it to do a search on one of the subaru sites like NASIOC for confirmation. Paul --- In subaruvanagon@..., DARREL PENNIGAR <darrelp86@...> wrote: engine was the only one that needed premium fuel, and that I should be able to use 87 octane in my '99 2.5 when I finally get it on the road? or South Carolina. To: subaruvanagon@...a one off year with higher compression and requires premium gas. Just wanted to let you know. I had a friend with that same engine, he didn't know it required 91 octane and blew it up on the freeway, not sure if the fuel had anything to do with it, but he said he sure wished he new it is suppose to run on premium! could wiring.use some input. I think I have most of mine figured out, except for notMy wiring harness was done a shop in Raleigh, but never installed, into itreally finished. I have finally found the time and courage to get weekend if Iand figure it out. I am hoping to put it in the vanagon this think.can get answers to a couple of questions. Brent, your site has been FaceBook, or coupleMicrosoft Messenger, or WebX from my laptop and interactively ask a yourof questions, if you would be up for it. You would not need video at wonderfulend, we could talk via telephone. A laptop in the shop is a SmallCarthing. been veryparts. This project has been going on for too many years, Tom has maybe wehelpful, as has SmallCar. Darrel, I am not that far from Charlotte, projectcould collaborate. I could even come to Charlotte. Did you buy your am infrom a hotrod shop south of Raleigh? You beat me to it if you did. I yourDurham. and arethread here Darrel, sounds like we are sharing some common problems April!!!!!working to the same end. [mailto:subaruvanagon@...]www.everybus2012.com SouthOn Behalf Of DARREL an 86Carolina. who hadVanagon Weekender. I bought this vehicle from a third party seller, engine wasvery little information about the vehicle, other than that the it wasfrom a 99 Legacy with 44,000 miles, and that he heard it run before description,removed from the Subaru. I talked to small car, and from my them. Thethey said it did not sound like the modification parts were from gettingseller did say that he possibly remembered that the owner mentioned with a Ya modification kit from a Subaruvanagon member named Bryan, spelled complete, butinstead of an I. The installation appears to be about 80-85% thethere are still some areas that have me at a loss. If I could have give meopportunity to look at a completed installation, I think it would campingenough information to get this project wrapped up in time for Charlotte,season. SO - I'm wondering if anyone within a 2-3 hour drive of andNC would have a V-gon with a 2.5 DOHC that I could come and inspect, can getmaybe make a few photos of the areas I have questions about, so I this vehicle on the road. Thanks in advance! Darrel |
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John
I did a Google search on ej25 and got to Wikipedia's great write up of the evolution of that motor. They speak to the problems associated with variations of that motor and the 'fix' that returned it to 87 octane and the year that happened. I too would avoid that ej25 that required 91 octane, for a few reasons covered in that write up.
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--- In subaruvanagon@..., "gouldp48" <gouldp48@...> wrote:
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Over the weekend I finally started opening up the wiring harness in the engine compartment of the Vanagon, and made some progress until I was overcome by a bad case of bronchitis. My very preliminary findings are: Whoever did the wiring modification had the proper gauge wire, but had a limited choice of colors - therefore no continuity of colors from the inside to the outside of the harness. I found that the 2 long wire pigtails that come out of one of the sub-harnesses are part of the charging system. Using the wiring diagram for a 99 Legacy, the large red wire goes to hot with ignition in the run position, and the small black wire goes to the alt. lamp. The other 3 wire pigtails that come out of the main harness are: red to battery voltage, one of the orange wires is hot when ign is in crank position, and the other orange wire is hot when ign. is in run position. I plan to re-verify this this coming weekend, and move on to the wires that go to and from the relay bank mounted in the engine compartment. In the meantime, however, I thought that I might ask if there are any preferred locations to splice these wires into the Vanagon electrical system, as opposed to just using the wiring diagram to find locations that would appear to be appropriate sources for each circuit. Thanks !!
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--- In subaruvanagon@..., DARREL PENNIGAR <darrelp86@...> wrote:
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Darrel,
It sounds like we are closing in on the same end, though my engine is not in the bus yet. Good luck. jim henry durham, nc 84 westy _____ From: subaruvanagon@... [mailto:subaruvanagon@...] On Behalf Of darrelp86 Sent: Tuesday, March 27, 2012 20:44 To: subaruvanagon@... Subject: [subaruvanagon] Re: Vanagon with a DOHC 2.5 engine in North or South Carolina. Over the weekend I finally started opening up the wiring harness in the engine compartment of the Vanagon, and made some progress until I was overcome by a bad case of bronchitis. My very preliminary findings are: Whoever did the wiring modification had the proper gauge wire, but had a limited choice of colors - therefore no continuity of colors from the inside to the outside of the harness. I found that the 2 long wire pigtails that come out of one of the sub-harnesses are part of the charging system. Using the wiring diagram for a 99 Legacy, the large red wire goes to hot with ignition in the run position, and the small black wire goes to the alt. lamp. The other 3 wire pigtails that come out of the main harness are: red to battery voltage, one of the orange wires is hot when ign is in crank position, and the other orange wire is hot when ign. is in run position. I plan to re-verify this this coming weekend, and move on to the wires that go to and from the relay bank mounted in the engine compartment. In the meantime, however, I thought that I might ask if there are any preferred locations to splice these wires into the Vanagon electrical system, as opposed to just using the wiring diagram to find locations that would appear to be appropriate sources for each circuit. Thanks !! --- In subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com> , DARREL PENNIGAR <darrelp86@...> wrote: appear, however that James and I have one common connection, however. Yes, James, this is the vehicle that was at the Hot Rod shop near Raleigh. The shop owner said that he thought that the wiring harness was sent to someone in Chapel Hill to be modified, but I'd be willing to bet that it was done by the same person in Raleigh thad did yours. Much of the wiring has been installed, but there are still a number of wires, almost all without connectors on the ends, that need to find a home. The wires had all been tagged with paper tags indicating where they went, but after sitting outside for a couple of years, the printing on almost every tag has faded to the point that it is illegible. One big question that I have is concerning 3 relays that are part of my harness. These are 3 identical relays that are mounted together on the left side of the engine compartment. There are wires coming from the harness bundle that attach to the relays, and then thereare wire pigtails about 10" long that come from the relays and are hanging loose. With time, I think I could trace out the rest of the wires, to determine where they go, but since the relays are not factory Subaru, I can't even guess what their purpose might be, or where the pigtails should be attached. Do you know, by chance, the name of the shop that did your harness modification? If they are still in business, maybe we could get a little assistance from them. In the meantime, I thought I'd try to make some photos of the different areas I have questions about in the next few days, and post them for inspection by any helpful group members. Thanks again, everyone for your assistance !! South Carolina. To: subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com> Date: Monday, March 5, 2012, 4:35 PMwiring. My wiring harness was done a shop in Raleigh, but never installed, notor Microsoft Messenger, or WebX from my laptop and interactively ask a couplevery helpful, as has SmallCar. Darrel, I am not that far from Charlotte, maybewe could collaborate. I could even come to Charlotte. Did you buy yourproject from a hotrod shop south of Raleigh? You beat me to it if you did. I am inare working to the same end.<mailto:subaruvanagon%40yahoogroups.com> [mailto:subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com> ] On Behalf Of DARREL Subject: [subaruvanagon] Vanagon with a DOHC 2.5 engine in North or Southhad very little information about the vehicle, other than that the engine wasgetting a modification kit from a Subaruvanagon member named Bryan, spelled with aY instead of an I. The installation appears to be about 80-85% complete, but |
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Jim - Sounds like we need to compare notes. My engine is in, and?the pcm and harness are in place with all the factory Subaru connectors attached to the engine components. I have opened up part of the harness and been able to determine what all of the pigtails are?that are hanging free.?What I still need to determine is the purpose of the 3?aftemarket relays that are mounted together in a relay bank?on the left side of the engine compartment. Was your ?harness modified by someone locally in the?Raleigh- Durham- Chapel?Hill area, and if it was, do you have?any printed info or wiring charts that came with it? Or do you know who did the modification? ?Also, does your harness have an aftermarket relay bank partly wired into the harness like mine does?
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--- On Sat, 3/31/12, James Henry <jch@...> wrote:
From: James Henry <jch@...> Subject: RE: [subaruvanagon] Re: Vanagon with a DOHC 2.5 engine in North or South Carolina. To: subaruvanagon@... Date: Saturday, March 31, 2012, 7:40 PM Darrel, It sounds like we are closing in on the same end, though my engine is not in the bus yet. Good luck. jim henry durham, nc 84 westy ? _____? From: subaruvanagon@... [mailto:subaruvanagon@...] On Behalf Of darrelp86 Sent: Tuesday, March 27, 2012 20:44 To: subaruvanagon@... Subject: [subaruvanagon] Re: Vanagon with a DOHC 2.5 engine in North or South Carolina. ? Over the weekend I finally started opening up the wiring harness in the engine compartment of the Vanagon, and made some progress until I was overcome by a bad case of bronchitis. My very preliminary findings are: Whoever did the wiring modification had the proper gauge wire, but had a limited choice of colors - therefore no continuity of colors from the inside to the outside of the harness. I found that the 2 long wire pigtails that come out of one of the sub-harnesses are part of the charging system. Using the wiring diagram for a 99 Legacy, the large red wire goes to hot with ignition in the run position, and the small black wire goes to the alt. lamp. The other 3 wire pigtails that come out of the main harness are: red to battery voltage, one of the orange wires is hot when ign is in crank position, and the other orange wire is hot when ign. is in run position. I plan to re-verify this this coming weekend, and move on to the wires that go to and from the relay bank mounted in the engine compartment. In the meantime, however, I thought that I might ask if there are any preferred locations to splice these wires into the Vanagon electrical system, as opposed to just using the wiring diagram to find locations that would appear to be appropriate sources for each circuit. Thanks !! --- In subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com> , DARREL PENNIGAR <darrelp86@...> wrote: appear, however that James and I have one common connection, however. Yes, James, this is the vehicle that was at the Hot Rod shop near Raleigh. The shop owner said that he thought that the wiring harness was sent to someone in Chapel Hill to be modified, but I'd be willing to bet that it was done by the same person in Raleigh thad did yours. Much of the wiring has been installed, but there are still a number of wires, almost all without connectors on the ends, that need to find a home. The wires had all been tagged with paper tags indicating where they went, but after sitting outside for a couple of years, the printing on almost every tag has faded to the point that it is illegible. One big question that I have is concerning 3 relays that are part of my harness. These are 3 identical relays that are mounted together on the left side of the engine compartment. There are wires coming from the harness bundle that attach to the relays, and then thereare wire pigtails about 10" long that come from the relays and are hanging loose. With time, I think I could trace out the rest of the wires, to determine where they go, but since the relays are not factory Subaru, I can't even guess what their purpose might be, or where the pigtails should be attached. Do you know, by chance, the name of the shop that did your harness modification? If they are still in business, maybe we could get a little assistance from them. In the meantime, I thought I'd try to make some photos of the different areas I have questions about in the next few days, and post them for inspection by any helpful group members. Thanks again, everyone for your assistance !! South Carolina. To: subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com> Date: Monday, March 5, 2012, 4:35 PMwiring. My wiring harness was done a shop in Raleigh, but never installed, notor Microsoft Messenger, or WebX from my laptop and interactively ask a couplevery helpful, as has SmallCar. Darrel, I am not that far from Charlotte, maybewe could collaborate. I could even come to Charlotte. Did you buy yourproject from a hotrod shop south of Raleigh? You beat me to it if you did. I am inare working to the same end.<mailto:subaruvanagon%40yahoogroups.com> [mailto:subaruvanagon@... <mailto:subaruvanagon%40yahoogroups.com> ] On Behalf Of DARREL Subject: [subaruvanagon] Vanagon with a DOHC 2.5 engine in North or Southhad very little information about the vehicle, other than that the engine wasgetting a modification kit from a Subaruvanagon member named Bryan, spelled with aY instead of an I. The installation appears to be about 80-85% complete, but [Non-text portions of this message have been removed] ------------------------------------ Yahoo! Groups Links [Non-text portions of this message have been removed] |
Brent Weide
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