>Hi Warren,

>I was wondering if it would be possible to included in the Files >section a folder on what exactly needs to removed from the VW. >There is alot of help on what to remove from the Subaru but i am >unclear on what needs to be left in the van and what needs to come >out. Is this possible or does it differ from year to year? Thanks >for the help. Should i post this to the list?

>eric V
>'90 Westie/'02 2.5l
 
Sure, go ahead and ask the list. I'm sure others will have more to add but, here's what I remember ( a little sketchy since I did it in Feb of 2001) :

1. Get a Bentley manual if you don't already have one. You will need to refer to the general instructions and pictures for removing the VW engine and tranny (if your van is 2wd....I left my Syncro tranny in the van. You will also need to refer to the VW engine wiring diagram in the Bentley. I made a copy to have handy.

2. DO THIS NEXT! Drain all cooling fluids from the waterboxer. Disconnecting a water hose is not enough. There's a drain plug on the right side of the engine that you remove with an Allen type wrench or driver. Its on the block in between the lifter tubes.

GENERAL TIP---when you disconnect wires in the engine bay, label the wire/connections that are left in the van with masking tape and a Sharpie marker. Refer to the Bentley wiring diagram and color codes if you don't know what something is. This will save you a lot of trouble later.

3. Under the rear seat, remove the VW ECU and unplug the wiring harness from the ECU and remove the ECU. If you can, pull the wiring harness out of the van interior. I wasn't able to do this, because I have a Syncro and the harness was pinned between the gas tank and the frame...tried lowering the tank ...no joy... I understand its easier to pull the harness from a 2wd van.

2. Now go to the engine bay and open the small black box in the upper left of the engine bay. Unplug the large round white plug. This plug carries all the wires from the engine to the insrument panel. Later you will want to cut the wires a foot or so to the engine side of the white plug and save it to splice Subaru wires into it. Don't throw it away or sell it with the rest of the harness. Disconnect the other wires in this box that lead to the engine. (Maybe someone whose done it recently will identify them specifically for you... I can't remember).

3. You will want to disconnect the wires to the fuel pump relay and remove it from the left side of the engine bay wall. Label the wires to the fuel pump.

4. Disconnect and label the wires that connect to the AC compressor (if you have one). Also disconnect the red "B+" wires to the alternator. I had two red B+ wires.

5. Disconnect all the wires connected to the engine. (fuel injectors , air flow pump, water temp, oil pressure sensors, idle control stabilizer etc.

6. Remove the idle control computer located in the recession behind the passenger side taillight.

7. Disconnect the cruise control servo, but leave the vacuum pump (if you have one) on the far right hand corner of the engine bay. You can connect a hose to the Subaru vacuum servo to have CC later with the Suby engine.

8. Disconnect and save the power steering lines. You can replace them with new ones from Smallcar or send yours to KEP to have the fittings changed.

9. Remove and save the oval burp tank.

10. Remove and save the tin splash guards on the right and left sides and also the one that goes across the rear of the engine bay. Some have been successful in reusing these. I reused half of the rear heat shield per KEP instructions but if you're using the Smallcar engine mount (recommended), you will not need it. You'll have to make another.
 11. Remove all the coolant plumbing with the einine up to the two main front to rear water pipes which are plastic from 86-91, (metal in 83-85).

12. Keep miscellaneous hoses and clamps you remove from the waterboxer. Some you can adapt or re-use later.

You should end up with the waterboxer, mostly intact, including the intake airbox, the AC compressor, alternator, power steering pump and, a complete wiring harness and computer. You can sell these parts to some lucky "stiff' later.

One caveat.....I would recommend you keep your VW powersteering pump and bracket (if you have one). Brian at smallcar has recently started adapting the pump to the Subaru to eliminate the somewhat annoying "whine" that the Subaru pump makes when connected to the Vanagon power steering rack (if you have ps). Most of us live with it (its the only thing I hear when my engine is at idle speed). Maybe Brian will make an adapter bracket available for sale to the public soon.

Others will probably have their recommendations also.

Warren C



Brent Weide
Senior Staff Architect - Corillian Corporation
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