Watercool the VW Bus - Busaru Engine Conversion Part 5

Busaru.com - In the VW to Subaru engine conversion, the cooling system is key. Let's look at cooling in this video and go through where to mount the radiators in the engine bay radiator design, as well as what radiators I use and how to get them plumbed. I used two Honda Civic radiators in this video but lately have been using one VW Scirocco radiator on the driver side and one Honda Civic radiator on the passenger side - The latest design really cleans up the install.
Follow along as we go through this very important step in the VW Bus engine conversion process.

[@rlprgp62]

Looks great. I had a Mazda Rotary in my 72 Bus I used a Rabbit radiator just like how you have it set up. I ran it for a couple of years then sold the set up to a guy with a bug. Thanks for sharing.

[@BeerMoneyGarage]

I have a rotary swapped 71 bus . having some problems with the cooling

[@rlprgp62]

Make sure you are using the correct OEM style 2 stage Mazda Thermostat. The other thing I ran into was having to mount a small or large surge tank above the radiator. I ended up using the plastic coolant bottle from a mid to late 80's Rabbit. The other thing I added was the Mazda RX7 engine oil cooler. I put a large coolant/oil cooler (Mounted above the transmission) in line of the coolant hoses to the oil cooler. I hope that made sense. I was going to add another VW Scirocco radiator to the other side of the engine compartment but I did not want to move the battery. Use the largest cooling fan you can get as some of those offered by like Jegs and Summit are not up to task. I looked more for the OE types like the 90's dodge intrepid, 90's 3.0/3.8L Ford Taurus. Again your build looks great, Have fun, above 4500 RPM Hang on!!!

[@BeerMoneyGarage]

thanks a lot for the input I just put the thermostat in there and it helped out a bit. I'm after the electric fans not doing their job. I got those cheap eBay fans ,I'm going to get some OEM Honda ones see if they help

[@rlprgp62]

Yes get an OEM quality fan they help alot. I tried a couple of the lesser "heavy duty" fans. I think I ended up using one from Ford taurus

[@SPACEFACE70]

Really good interesting video ! Looking forward to the next bit. Took my subaru engine and loom out at the weekend took about ten hours. I have been stripping the wiring loom sections out now. What a pain lol. Keep the vids coming mate..

[@GarageTime]

Really want to type this on one of our busses. Great information, Thank for sharing.

[@kingbob2021]

Can we put the radiator infront of the car like the kombi 2013 one ? Plz reply i need some suggestion i want to make my kombi similar like the 2013 one.

[@Petah30]

do you prefer this methoud or the belly radiator?

[@Itoyz79]

Nice clean set up ! Could you provide me with details (part #'s) & where I can order these radiators & cooling fans including all the accessories needed (radiator caps, hoses, pipes....etc) ? I'm also interested in acquiring the corner tabs (requires welding) from you !! Looking forward to your next video !!!

[@Busaru]

Hey Itoyz, thanks for the compliments on the series. I am putting together the part numbers and kit pricing (which will include the radiators with fans and tabs) soon. It'll still be a few weeks to a month before I'm ready to start shipping them out though. At the end of the video series I'm planning to do a full article series with more information - check out boxerswaps.com and the subaruvanagon section for a preview on whats to come. It'll have a lot more info than what I can squeeze into a short video.

[@Sycoticification]

Do relocate the battery?

[@kieren3933]

Hi does this work with out airlocks

[@TairnKA]

For some reason I thought the fans were on the other side of the rads but looking back I see their on the engine side (pull in). Was it lack of space on the other side (push thru) why you have them that way?

[@brentredmon67]

Awesome video series! I've probably watched them five times over. It really makes me happy that you're delving into something that it seems like no one else has done before. I'm 16 and about to get a mid 70's Westy myself, and hope to do a swap pretty soon after. Although I don't have access to a Subaru engine, I do have a VW Jetta 1.9L TDI engine at my disposal that I've heard is a pretty popular swap to do as well. Do you think that the '97 Honda Civic radiators would be compatible with that particular engine? Or are they specifically geared towards Subaru engines?

[@Busaru]

Hey Brent, sounds like a great project. The radiators aren't specific to the Subaru and will probably work pretty well with the smaller, cooler running, diesel. I would make sure the in's and out's match up okay before going with them though. Take some videos as you convert, I would love to see that!

[@TheJReth]

Should air flow onto engine, mine keeps overheating, 213degrees to 221. I'm in Idaho and it's here. TY

[@mikeyvans5177]

What's you're plan for changing the breaklights when they go? Access port in the battery tray?

[@jaredwaddell328]

Did you move the battery to install these radiators? I have a '78 and the battery would be behind the passenger side radiator. I have a WRX engine in mine and the battery lives a very short life due to evaporation of the liquid inside, probably because of the heat in the engine compartment.

[@mschiffel1]

Do the fans suck air through the radiators into the engine bay or blow through them ?...I'm going to do a low tech swap using a Chevy ll inline four banger, 90 hp and 153 cubic inches. (2.5 L)...I already have Kennedy's adapter and flywheel kit...I'm using this lump because I already have it and my bus has a very sick 2.0L..I like being different..all I really want is more torque and heat.

[@dillonv2603]

Mick, do you mind sharing the dimensions / material of the cross over pipe when connecting to the top filler? Also, are you using Tom's thermostat?

[@Busaru]

Hey Dillon, its been a long time! I'd love to hear how your project is coming along. The cross over pipe is galvanized steel (which has lower reactivity than stainless believe it or not!). The easiest place to find this is at the home store - it is 1.25" EMT electrical conduit. The length is going to be a little different for every swap but I'd just buy a stick of conduit and cut to length. If memory serves, its around 36" depending on how much rubber radiator hose is used. I have not heard of Toms thermostat. I should contact him about that. Any benefit?

[@OverlandingJoy]

I have an 82 Transporter - aircooled. Is it possible or even practical to swap the Sub engine and plumb water cooling system?

[@Busaru]

It's absolutely possible and I've done it. It takes a little more work as you'll need to find a donor Vanagon and pull all of the cooling system and install in yours. You have fantastic results as the air-cooled vans were pretty underpowered, even compared to the 1.9 WBX. You can check out my articles at busaru.com (boxer swaps.com) here - www.boxerswaps.com/aircooled-vanagon/aircooled-vanagon-introduction

[@OverlandingJoy]

Busaru Thanks for the quick response. I've watched all of your videos and I believe this spring will be the beginning of my project. I'll keep your site bookmarked and will revisit soon. Great work!!!

[@Busaru]

Man Living Naturally I took a look at some of your chemtrail videos - very interesting!

[@OverlandingJoy]

Busaru You've probably noticed them in your area but didn't give much thought or attention to them. I worked in aviation for over 20 years and these are a relatively new phenomenon. Most people don't want to go too deep into the rabbit hole, so to speak - and rather enjoy living in bliss. Regarding my air-cooled 2.0. I'm really torn between upgrading to a Sub or the like - and then sometimes just thinking that I'd rather keep the van original. It has 78K original miles on it and if I could just increase the HP or performance I would more likely be satisfied with that. I'm not a mechanic so forgive my ignorance - but can this motor be bored out to realize a worthwhile difference?

[@Busaru]

Regarding your engine, you may want to call GoWesty and see if they have a performance air-cooled engine, or know of anyone that does performance work on them. My guess is that it'll be pricey, but I get surprised often.

[@michaelperry2303]

Loving the videos. Makes me think I could handle the swap out. Just pricing parts out now and hunting for a Subaru. What do you think about the logistics of using a 1998 Legacy? I think it's the EJ25 engine? It's AWD and automatic and needs transmission work but that shouldn't concern me as it's just the engine I want right?

[@Busaru]

You're not too concerned with the shape of the donor vehicle aside from the engine. BUT, a poorly taken care of car could mean the engine wasn't taken care of. Might want to do a compression test, check fluids, etc. The standard engine is 2.2L but could have a 2.5 if its an upgraded model.

[@charlesmcmillan8324]

Probably stupid to ask - but I am curious do you happen to have a part number or such for the Scirocco Radiator or a suggestion for which company to use? I am looking for a radiator that will fit for use in my 69 Bug but when I look for Scirocco Radiators none of the images I see match the one on the video.

[@Crowntrout]

Charles Mcmillan www.rockauto.com/en/moreinfo.php?pk=272083&cc=1285590&jsn=8391 www.ebay.com/itm/Aluminum-Radiator-for-VW-GOLF-GTI-JETTA-MK2-Corrado-Scirocco-Coupe-1-8V-86-95/201485961017?pageci=23e53bd0-99e7-4b96-9a28-80fcc1938f67

[@michaelhawthorn9749]

hi. just a quick question. I noticed with these radiators someone was having trouble cooling a 2.5 engine. would it be sufficient for 2x 3 row radiators rather than the 2 row that you use? wondering wether the 2 x 3 rows together would be sufficient enough for the 2.5 engine im putting in my late bay and love your radiator placement idea as I will be lowering mine to the floor! thanks in advance and great tutorials by the way! thanks mick

[@Busaru]

3 row will probably cool a lot worse since it'll restrict airflow. I haven't experimented with Single row but Subarugears had claimed that they have a customer running stock Honda radiators (single row) cooling an SVX engine. Now this engine is coupled with a Subaru transmission but still - that's a massive power plant.

[@jennifercharlton-dennis6763]

Hey man great series so far! (this is my wifes account) I haven't made it through all the vids yet so you may have answered my question. Do you have any scoops on the outside of the bus by the radiators or do they just use the air in the engine compartment?

[@Busaru]

Thanks! I don't have scoops but its not a bad idea, especially for warmer climates - The more airflow the better, although I've heard the argument that positive pressure doesn't help cool as much as vacuum below/behind the bus. Its definitely worth exploring.

[@felixalvarez3055]

Question. Have you tried running your radiators in parallel instead of series and seen any difference? Maybe improvments? Also in the outlet of the left radiator I see that it's sitting a lot higher than the inlet connection, can this decrease the radiator potential due to (from basic observation and taking in physics of gravity) water on the lower parts not being able to make it to the outlet?

[@Busaru]

Hey Felix, good points! I went with this design primarily because of "off the shelf" handiness. If going with custom radiators (or altering the Honda rads) it would be best to have a high coolant entry point and low discharge - it's all an experiment at this point as no one seems to have a perfect system for all conditions. I know some folks who've run these rads in parallel but no significant changes to cooling temps. 85-210 seems to be the range from normal to high temps. Are you working on a project, I'd love to see any improvements - all contribute to the knowledge base. Cheers!

[@felixalvarez3055]

+Busaru Thanks for the reply, I love your vids. Yes I am currently working on putting a 2.5 in a 78 bay window as the original 2.0fi seemed to not sound like it ran right even after rebuilding the whole thing. I'm now thinking of using Geo Metro radiators due to its compact size able while standing up right. My next hick up is deciding what to do with the transmission situation. I'm hoping to use the subaru automatic but we'll see.

[@Busaru]

+Felix Alvarez Great idea on the Metro rads, I'd love to see a picture of those when you get them mocked up - any chance you can post a pic up on the boxerswaps forum, or send me a pic at [e-mail]? SubaruGears offers a kit for the Subaru 5 speed but I don't think they have a kit for the auto - that would be great if you could develop a reversed crown and pinion for the auto - I'd buy one!

[@loudluggageco]

+Felix Alvarez I looked up those geo metro / suzuki swift radiators and I believe the are actually larger? correct me if i'm wrong, or provide me with a link? i'm doing a ej22 swap in a 1957 bus : ] thank you guys and BUSARU dude you are the man thank you for the inspiration!

[@felixalvarez3055]

+Loud Luggage Co. The Geo and Suzuki radiators are about... 1 inch smaller in diam and length (12.8"x 12.9") while the civic ones shown here are 13.7"x 13.6". Not very much of a difference at all. I am tossing around the idea of using a motorcycle radiator like from a Goldwing, but I think if i get smaller it may not be able to keep up with the heat output. I'm still at the drawing table for putting in the 2.5 with the Subaru automatic transmission, I may end up (to simplify repairs in the future) cutting just a little into the cab and putting the engine facing forwards. I wish you the best of luck,

[@erikrhendrickson]

How long should the crossover pipe be? Is a 3' length long enough?

[@Busaru]

+Erik Hendrickson Hey Erik, that should be long enough.

[@johnny85er]

question: where do you put your battery/batteries?

[@Busaru]

+johnny85er If going with engine bay rads I put the battery under the rear seat.

[@johnny85er]

my 78 Riviera is in need of a new motor, I've been thinking about going Subaru for sometime, and after a lengthy discussion at work, I came back & rewatched all your videos. I'm still trying to figure out what would work best with the radiators. Underbelly seems the 'least intrusive'... Thanks for these videos, they are quite the resource. I will report back if I make any progress.

[@Busaru]

+johnny85er You definitely won't regret it. I'd say go belly rad if you're going to stay mostly on pavement. If going off highway frequently then I'd definitely go engine bay rads. Both designs have their place. Good luck on your project!

[@loudluggageco]

how's this bus running with the two side radiators? i'm getting close to starting mine!!! similar but different….: ]

[@Busaru]

+Loud Luggage Co. They work awesome! I don't live in Phoenix though, that heat may take its toll on all bus radiator systems!

[@chrisdamewood7438]

Awesome work on the vans and the videos! I am learning so much thank you! Have you put together a busaru engine installation kit? If so, i need to know where i can get one! Thanks man!

[@Busaru]

+Chris Damewood I offer the crossmember, the Throttle Body Reverser, and the Vehicle Speed Sensor. I can also help with a wiring harness. You can find that stuff at Busaru.com/busaruparts For the adapter plate and exhaust you should go with Kennedy Engineered Products - just google their stuff.

[@a914freak]

You would be better off using the factory mounting posts on the radiator and finding a way to weld the actual brackets the hold the rubber grommets that those posts go into. By hard mounting the radiator you risk developing cracks through vibration which is why they mount the radiator using the posts and rubber grommets to isolate it from vibration.

[@Busaru]

I haven’t watched this video in years and you got me thinking. I’ve been mounting them differently as designs have progressed but haven’t updated folks on how I’ve been doing the past 3 years or so. At some point I’ll document another swap showing my updated method - which is very much like what you explain. Thanks for the comment.

[@patrickmicallef5071]

WHEN THE SYSTEM IS INSTALLED ,DOES IT NEED A COOLANT RESEVOIR ? IF SO .HOW TO INSTALL ?

[@Busaru]

+Patrick Micallef it needs a coolant overflow tank. You can mount one to the firewall if you'd like.

[@theecheesyshark]

other than suburu engines what other engines can you put in?

[@Busaru]

Kennedy Engineered Products has a list of other options but I don't have experience with any others.

[@joerobertson7047]

+Popeye spinach Zetech ford 4cyl is a popular swap.

[@glassblastcollision]

I used two civic rads too!lol

[@type2523]

I'm sure that you have overheating issues !

[@Busaru]

+Κώστας Λεούσης Ha! I'm sure you are.

[@a914freak]

Those are not crossflow radiators, and setting them up that way is rendering half the radiator useless. A cross flow radiator would have the inlet at the very top and not in the middle and the outlet would be at the bottom. I would suggest you let people know this is not the proper radiator to buy for this application.

[@Busaru]

Sheesh, very critical! I have them in my personal bus for 5 years now without issue. I have started installing a scirocco radiator on the left side and using the porthole to mount the air filter - makes for a very clean install - cleaner than the 2013 design in my opinion.

[@Busaru]

Quick question - have you found an off-the-shelf radiator that would work better than the Honda? I’ve tried quite a few but have yet to find the magic combination. The Left Scirocco/Right Honda is cooling the best in my experience. I prefer to direct folks to off the shelf versus custom radiators. Let me know what you’re using.

[@nasalimbu3078]

Thymidrymic AC