Exhaust. Cooling. - Subaru Vanagon Engine Swap Part 8

[@davidbasurto9024]

I’m looking for the adapter Plate and Fly wheel to 1983 VW Vanagon to the Subaru Engine 2.5

[@SlugsVw]

Hey Mick, enjoying all your videos. I have 1983 Air cooled Vanagon, looking to swap the same model engine. I was wondering where I would place the radiator? Would I have to place it up front?

[@forthwithtx5852]

I'm trying to make this work with what I have in WBX parts and Subaru donor parts, but I'm not quite getting it together. The upper hose you show, I have, but the diameter isn't really conducive to slipping over the engine hose fitting. Maybe it's just too old and not flexible enough anymore. I also have the coolant bottle reversed 180 degrees from your example, which is more like the example on your Busaru page. Perhaps the clearance is different on the 2.2L vs. the 2.5L? I may reverse it. but I'm going to see if I can overcome some of the fitment issues with generic ribbed hose first. I also opted to keep the side tins, which will slip under the KEP mounts after flattening out the flange. They aren't bolted in place on the frame, but the KEP mount clamps them securely. It might make things a little more difficult for hose routing from the T-stat housing connection, but I really like the idea of having them there (Note: I had to notch out the tins in the area of the KEP crossmember, but I will fill them in with a "humped" piece of galvanized sheet steel).

[@Busaru]

I can't wait to see your cooling tin sheet metal combo - I bet that'll look pretty good. As far as the coolant hose routing goes, it's just a puzzle. If you're having trouble slipping the 1.25" hose over the Subaru inlet and outlets, try putting a very small amount of grease on the inside of the rubber and heating with a hair dryer or heat gun. That should give you plenty of give to slip over the ridge on the coolant manifold.

[@forthwithtx5852]

I'll try that. It did come to mind. I dove into the wiring harness tonight. Removing sheathing, segregating the things I'm pretty sure I don't need. Haven't cut any wires yet! There is a unit on the same branch of the barometric pressure sensor that I am baffled about. Says "JECS" on it. Per your vids so far, not among the things I need, and there is a third relay next to the green and brown connector relays that I want to know more about before I snip it out. Just beginning...

[@Busaru]

Forthwith Tx I believe the JECs unit is a resistor but not totally sure without seeing it. The third relay is the fan relay I believe. Just work from the computer out, basing your decision to cut on what the pinout document says. And the most important thing - just take your time. Good luck!

[@forthwithtx5852]

I was able to expand the hose by boiling the end and slipping a tee into it until it cooled. It fit much easier on the engine hose fitting with some silicone grease after that.

[@Busaru]

Forthwith Tx Sweet! Good work, looking forward to seeing your swap when it's all said and done.

[@KareemAdnan]

Nice job with all of your guides/videos. Rare that people that know as much as you do mechanically can also produce great content! Where did you get the heater circuit Brass barbed tees from? I can find 5/8 tees that are the same size on all three ports but I can't find ones like you show that have a reduction for the middle port. What is the reduction that you did?

[@Busaru]

+Kareem Adnan Thanks Kareem! So I go to the plumbing isle at Home Depot and find where they have PEX fittings. All you are trying to do with the reduction is allow most of the coolant to flow through to the heater cores so anything 3/8+ would work for the bypass. I hope that helps!

[@shane8793]

Not sure if your still checking in on these but I have my swap set up like this. I added the rear heater bypass and the front heater never gets warm now. Any ideas?

[@allanschmidt2812]

Hi Mick. I'm from costa rica. I had installed a ej25 in a vanagon. But i have problem with coolant flow. Do you have a coolant flow diagram. Please and thanks for your videos.

[@Busaru]

+Allan Schmidt I can explain it quick - coolant out to rad from top hose of engine, coolant into engine from bottom hose (thermostat housing). Heater circuit - coolant out from coolant manifold (under intake), coolant in from heater to thermostat housing. Hope that helps!

[@allanschmidt2812]

Thanks, Mick. it happens that the coolant flow is very weak and almost does not move. Please help. I ran out options. Jajajajaj

[@Busaru]

+Allan Schmidt Is your thermostat opening all the way? Take it out and see if you get better flow. If it's still slow then you probably have a blockage in the radiator.

[@marshens5844]

Hi, can you provide the link where i can buy the exhaust? And one more question is there a cad drawings for for a engine support, i want to weld it myself. Regards

[@Busaru]

+Mars Hens Hi Mars, contact KEP for the exhaust. No CAD files for the crossmember. Good luck in your build!

[@davidbasurto9024]

Yes busaru. knows everything he told me by with KEP Kennedy in general 👍

[@Chris530-65]

Do they make one that fits a bug?

[@s.o.m.e..g.u.y]

Hi Mick, How is this cooling system working out for you? I'm planning on copying your plumbing, since I wont be running a reverse coolant manifold.

[@Busaru]

+Matt Jackman hi Matt, this is generally how I do my cooling systems on the Vanagons - it works great. I can't personally justify the expense of a reverse manifold for looks.

[@maryannchapman3477]

Do you do swaps for the public? I sent you a pm on your fb page. Had a few questions.

[@Busaru]

Hi MaryAnn, Thanks for the comment. You can always email me at [e-mail]- that's definitely the easiest way to communicate for me. Talk to you soon.

[@brese73]

sent you an email. do you have a video tutorial to hooking up the AC lines? I have a 1991 vanagon already converted to ej22

[@Busaru]

Nothing yet, I'll have to do one at some point though.

[@maryannchapman3477]

ok i see boxerswaps.com.

[@brucewayne2773]

Subaru motors suck, they blow headgaskets, they burn oil. They may have the extra hp and torque. I went with 2.3 GoWesty motor which has been reliable thus far for 80k miles now.