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Old 12-21-2011, 11:22 AM   #1
Slow Steve
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Default 96 Impreza 2.2 into a 67 VW bus

Hey all! I just picked up a 96 Impreza wagon with a 2.2, 135k miles. The car is running and complete. The owner's son hit a deer so she wanted to get rid of the car; this is where I come in. My plan is to put the engine in my 67 VW bus so that I have modern technology wrapped in a vintage shell. I also picked up front/rear Porsche 944 brakes. I love my bus, but let’s face it... it's not reliable and the brakes are terrible. I want to do long distamce camping/travel/fishing trips with the family but not in its current condition. I know that people have made cross country trips in vintage VWs in the past, but why risk stranding your family when you can potentially avoid it?

I plan on doing a complete stock setup, ECU... the whole 9 yards. So is there anything I should look out for before I start to tear this baby apart? Does anybody have the wiring diagram for this conversion they would be willing to share? Any thanks would be greatly appreciated.

I will also be parting out everything else transmission, glass, doors… you know the deal. I will post it up in the classifieds section, but if you want something let me know. Make me an offer, I will probably take it. Or, if anybody wants the whole thing, I'd sell it that way too. Clean title.

Thanks
Steve
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Last edited by Slow Steve; 12-21-2011 at 06:19 PM.
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Old 12-21-2011, 04:44 PM   #2
jzk25
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Have done lots of these swaps, half the Kombi's in Australia have EJ's in them now.
I specialise in wiring prep for this sort of thing(in Australia) and people send me there subaru loom and I strip the engine wiring from the main loom and prep it for fitment to the VW. Makes it easy for the guy fitting the engine.

Stuff you need to do-

- make a front engine support, the old engine will not be supported at the front, the subaru engine will need to be. A bar running from rail to rail with appropriate bracketry will sort that.

- Gearbox in the old girl will not be appropriate for the EJ engine, the clutch will be too small and the ratios are completely wrong for a torquey 2.2. You should get a 2l Kombi box or there is also a place over here called subarugears.com that makes reversed CW&P for subaru boxes to use in kombi's.

- Radiator - We mount the radiator under the belly of the bus. This maintains the look of the old bus and shortens the radiator piping. It requires a bit of customising, but so does most of the job so be prepared.

- Coolant tanks - Subaru engines are the devils work to bleed in a subaru, they are 10 times worse in a kombi. Some things that are mandatory with the kombi-EJ cooling system . Use a header tank as the highest point. This needs to fill the bottom hose not the top hose. The heater hose circuit must be freeflowing all the time, if a heater is used you must use a T piece between the two hoses close to the engine. There is a throttle body heater circuit that is intercepted to bleed the top hose outlet of air back into the header tank. In Aus we delete the whole thing as it never gets that cold here but you may still need it. BE VERY CAREFUL WHEN BLEEDING THE COOLING SYSTEM, IT IS NOT EASY AND TAKES MANY ATTEMPTS.

- Speed sensor - You need a speed sensor for the ecu. VDO part number 412-009 will screw to the speedo head and the cable screws into it.

- Adaptor plate - plenty of these available, smallcar performance makes some good stuff.

- Shortened sump - not mandatory but always recommended, smallcar also make a nice cast version of this.

- Custom header pipes. You pretty well have to make these from the head flange back, they need to be very short and the subaru pipes are not.

Plenty more but digest that for a while.

Here's a 70's Kombi I did last week. http://www.facebook.com/media/set/?s...8393362&type=1
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Old 12-22-2011, 01:10 AM   #3
Slow Steve
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Thanks for the info mate. I am going to use the heater and plan to hook up the A/C, so I definently appreciate the heads up on that. Nice radiator set up, and nice welds too! Do the two individual air scoops work better than one, or is it a strength thing? I'm glad you mentioned fabing up motor mounts, I was thinking about just hanging it off the trans like the VW motor; but will weld up some like the ones you have in the pics. Do you shorten the oil pan or leave it if the bus is stock height? If you shorten it, do you make it wider so that you can keep the same or more oil in the pan? And good info on the speed sensor. BIG thanks!

I guess I'm going to really take my time on the wiring harness and mark everything I disconnect, and cut out all the unused wires that go to the parts not needed. I have some more questions but will spread them out...

Do you keep up with motogp, or US superbike? Stoner kicks ass! and I watched Mladin race many times and got his autograph a time or two.
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Old 01-04-2012, 06:46 PM   #4
Slow Steve
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I finally got some time today on the subie today. It's been in the 30's today, so progress was slow. The nicest part was inside the wagon removing the wiring, nice and toastie with the heat coming off the mega bright light I was using. I will post up pics later today. It's not a pretty site... I took alot more than I thought to get the harnesses out, PIA! But almost done, I will get the rest when I pull the engine. THEN the real fun begins with sorting it.

What I did today was I kept all the connectors unless it went to the doors, lights, wipers etc... then I cut those off to make it easier later.

Question to those that have done this before. Is everything from the front seats back useless and I should just cut? The airbags deployed from the PO hitting a deer so no worries there.

Thanks
Steve
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Old 01-19-2012, 12:02 AM   #5
Slow Steve
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Ok, finally got the correct wiring diagram for this. Hopefully have the wiring sorted by this weekend. I was going through the o2 sensors, which leads me to my next question. Do I need to run both o2 sensors? And do I need to run catalytic converters, or could I just run them straight in the exhaust tubing? Thanks for any info!

Last edited by Slow Steve; 01-19-2012 at 12:09 AM.
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Old 01-19-2012, 03:03 AM   #6
ciper
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Slow Steve do you have a picture of the donor car? Consider running a catalytic converter even if its not required because they can get pretty stinky and the exhaust flow rate from the 2.2 is fairly low. Replace the plate on the back of the engine with an updated metal unit so you dont get leaks later on (35$ part)

Quote:
Originally Posted by jzk25 View Post
- Speed sensor - You need a speed sensor for the ecu. VDO part number 412-009 will screw to the speedo head and the cable screws into it.
Wow. I had no idea this existed. A BUNCH of EJ power VW breadboxes in California have a constant CEL because there is no speed sensor signal.
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Old 01-19-2012, 09:24 AM   #7
Spigatelli
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In a Splitty? ouch. I have thought about doing it in my Ghia.
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Old 01-19-2012, 10:55 AM   #8
Slow Steve
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Quote:
Originally Posted by ciper View Post
Slow Steve do you have a picture of the donor car? Consider running a catalytic converter even if its not required because they can get pretty stinky and the exhaust flow rate from the 2.2 is fairly low. Replace the plate on the back of the engine with an updated metal unit so you dont get leaks later on (35$ part)



Wow. I had no idea this existed. A BUNCH of EJ power VW breadboxes in California have a constant CEL because there is no speed sensor signal.

Thanks for the tip on the rear plate! I will post some pictures up once I get home later, threads without pictures stink I don't have much but will post as I go. This is my first conversion so the progress will be slow with lots of questions.

I was wondering about the catalytic converters and o2 sensors because I read somewhere loooong time ago that you didn't need to run a rear o2 sensor due to it being for emmisions and wouldn't effect the performance of the car. It would throw up an error code, but it wouldn't harm it. Is that correct?

Last edited by Slow Steve; 01-19-2012 at 03:10 PM.
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Old 01-19-2012, 10:58 AM   #9
Slow Steve
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Quote:
Originally Posted by Spigatelli View Post
In a Splitty? ouch. I have thought about doing it in my Ghia.

Oh yeah. Modern performance wrapped in a vintage shell
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Old 01-20-2012, 07:30 PM   #10
Slow Steve
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Ok, I dug up the thread of the bus from KCW when I brought it and brought it home. I have done a little more to it, but it has been slow due to going back to school and now studying for the boards. This bus was crusty. Keep in mind that I have never owned a welder before picking this bus up. I bought the bus, LOTS of repair metal, and welder.... and went from there
Check it:
http://kustomcoachwerks.com/forums/v...er=asc&start=0
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Old 01-20-2012, 07:45 PM   #11
Slow Steve
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Here's some pictures of the donor car, engine and current wiring status.

Donor car, as you can see PO hit a deer that hit windshield.. parts of deer can still be seen. Airbags went off and everything:


2.2:


Headache :


Sorted... mostly. I still need to shorten/lengthen/fuse panel:
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Old 01-20-2012, 09:55 PM   #12
RSti_Spyder
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Hey Steve, I posted pictures of the Small Car Performance pan in the engine classifieds here on Nasioc. Let me know if you want it, you know you need it...
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