"Strawman"
The .01 spec for VolksarU, with comments. This is a starting place based on hundreds of hours of research on many worked examples and interviews with those who have already done a conversion.Reiterating the overall goals (RDCL):
- Reliability - Regular driving is just 'no problem.' You shouldn't have to coddle it or fiddle with it to keep it running, or fret about overheating it. If any compromise in design or execution threatens reliability, it's out.
- DIY Friendly - If you can't buy a necessary adapter from a vendor or fabricate a part yourself with common home power tools or have them fabricated locally to the VolksarU specification, its out.
- Cost Control - Off-the-Shelf parts are our preferred source for components.
- Longevity - This is 'no problem' in the long run, which for our definition is 100k.
VolksarU is intended to be an emissions compliant (for the model-year of the engine) OBD2 solution for daily town and highway driving. In California, VolksarU would not be legal for 1976-1979 models which must retain their original emissions system (and thus, their original engine.) As of this writing, a Subaru powered VW which retains all of its emissions components would sail through standard emissions checks.
Vendor selection is limited in North America at this time, which is probably why the majority of Subaru conversions for Air Cooled Buses have been custom fabrication, or less politely, "hacks." (Some have been artwork, but they're the exception.) There are several vendors which can sell or install kits for the conversion of Vanagons. Only one of them expressed an interest in fabricating standard components for the late "highlight" Air Cooled Bus: Rocky Mountain Westy. So your choices are RMW, or find a local fabricator to custom build many of your conversion parts for you. Either is fine. The RMW components are known to work.
Sections:
0.1-0 General Design
0.1-1 Target Vehicle
0.1-2 Target Engine
0.1-3 Engine Management
0.1-4 Engine Wiring Harness
0.1-5 Transmission Adapter
0.1-6 Starter Adapter
0.1-7 Starter
0.1-8 Throttle Valve Reverser
0.1-9 Engine Support Bar
0.1-10 Cooling Solution
0.1-11 DIY Fabricated
0.1-12 Fan Support
0.1-13 Fans
0.1-14 Coolant Plumbing
0.1.-15 Exhaust
0.1-16 Air Intake
0.1-17 Tools
0.1-18 Auxiliary Hoses
0.1-19 Costs
0.1-0 General Design
Air intake is via the two intake vents, which travel down the inside rear corners of the bus engine compartment, terminating in the battery trays. (The stock battery on the right hand side is relocated to beneath the rear seat in this design.) Having no where else to go, the air turns inboard, is held in check from flowing around the radiators by frames, baffles, and bulb gaskets, leaving it no where else to go but through the radiators, through the fan cowl and into the engine compartment. The compartment, being much larger than the engine, has an open area all around the engine for the heated air to escape through, down and behind the vehicle.
The primary coolant path is out of the top of the engine to the left rear, into the bottom left inlet by the rear hatch, then forward and around the internal double pass and out the outlet directly above the inlet, at the top rear of the engine compartment. The coolant then crosses the compartment through an aluminized steel tube and then takes the reverse trip (top right rear inlet, forward, then down and back) to outlet near the thermostat housing at the bottom right of the engine.
0.1-12 Fan Support
0.1-13 Fans
0.1-14 Coolant Plumbing
0.1.-15 Exhaust
0.1-16 Air Intake
0.1-17 Tools
0.1-18 Auxiliary Hoses
0.1-19 Costs
Air intake is via the two intake vents, which travel down the inside rear corners of the bus engine compartment, terminating in the battery trays. (The stock battery on the right hand side is relocated to beneath the rear seat in this design.) Having no where else to go, the air turns inboard, is held in check from flowing around the radiators by frames, baffles, and bulb gaskets, leaving it no where else to go but through the radiators, through the fan cowl and into the engine compartment. The compartment, being much larger than the engine, has an open area all around the engine for the heated air to escape through, down and behind the vehicle.
 |
| An EJ22 adapted into an early 'lowlight' Bay Window bus illustrates much of the anticipated design of the primary cooling loop, including the general placement of scirocco style radiators and Mk1/Mk2 VW fan housings. This installation is only partially complete in this picture, but essentials of the coolant loop are present. |
0.1-1 Target Vehicle:
1973-1979 Type2 Kombi, Passenger, or Campmobile models
0.1-2 Target Engine:
Subaru EJ22E 1995-2004 SOHC Normally Aspirated
0.1-3 Engine Management:
Subaru Stock ECU OnBoard DiagnosticsII (OBD2) compliant
0.1-4 Engine Wiring Harness:
Stock Subaru, modified for length and layout. The prototype is being performed by Jeff Robenolt for the Volksaru Project.
Note: This is one conversion you should leave to a professional, or to a hobbyist who processes a large number of them. If you can't solder, use continuity test equipment or are unsure of your ability to validate your work on the harness before you try to use it to start the engine, you shouldn't attempt this wiring work yourself for purposes of economy. Pick up some extra shifts at work, or save until you can pay to have the work done. This portion of the work should not be your first try.
OBD2 Trouble code interface: Smallcar.com.
Vehicle Speed Sensor, Rocky Mountain Westy.com
0.1-5 Transmission Adapter: As sold by Rocky Mountain Westy.com Request "Subaru Engine Adapter Kit- Manual Trans, Part# OF-001." This unit was selected because of the reputation of the manufacturer, Outfront Motorsports. This adapter is for the 091 transmission used from 1976-1979 model years. Transmission adapters for earlier 002 transmissions (1968-1975) are also available from the same vendor, but require a different starter.
0.1-6 Starter Adapter: As sold by Rocky Mountain Westy.com. Request Part# WV-001. This permits the use of a Bosch SR0408X/409X starter (2kW) as used in 1996-2003 VW TDI Manual Transmissions for use with the 091 Bus Transmission. The use of a much higher compression engine than the original VW engine requires a much higher Torque starter.
Note: This is one conversion you should leave to a professional, or to a hobbyist who processes a large number of them. If you can't solder, use continuity test equipment or are unsure of your ability to validate your work on the harness before you try to use it to start the engine, you shouldn't attempt this wiring work yourself for purposes of economy. Pick up some extra shifts at work, or save until you can pay to have the work done. This portion of the work should not be your first try.
OBD2 Trouble code interface: Smallcar.com.
Vehicle Speed Sensor, Rocky Mountain Westy.com
0.1-5 Transmission Adapter: As sold by Rocky Mountain Westy.com Request "Subaru Engine Adapter Kit- Manual Trans, Part# OF-001." This unit was selected because of the reputation of the manufacturer, Outfront Motorsports. This adapter is for the 091 transmission used from 1976-1979 model years. Transmission adapters for earlier 002 transmissions (1968-1975) are also available from the same vendor, but require a different starter.
0.1-6 Starter Adapter: As sold by Rocky Mountain Westy.com. Request Part# WV-001. This permits the use of a Bosch SR0408X/409X starter (2kW) as used in 1996-2003 VW TDI Manual Transmissions for use with the 091 Bus Transmission. The use of a much higher compression engine than the original VW engine requires a much higher Torque starter.
0.1-7 Starter: For 1976-1979 091 Transmissions with the Starter Adapter described above: Bosch SR0408X/409X starter (2kW) as used in 1996-2003 VW TDI Manual Transmissions.
For earlier 002 transmissions (1968-1975) use the IMI 101N Hi-Torque Starter without a starter adapter.
Note: There are reports that IMI 101N may not produce enough torque at 1.4kW to turn over higher compression Model Year 2000+ Subaru engines, EG33 SVX, or H6 engines, or the "Franken-engine." It should be sufficient for EJ22 1990-1999 non-turbo with a Compression Ratio of 9:1.
0.1-8 Throttle Valve Reverser:
As sold by Rocky Mountain Westy.com Phone sales only at this time. Call and request "Throttle Valve Relocator." This unit was selected because it is made from cast aluminum to produce the tightest radius possible, essentially bringing the throttle valve assembly in directly over the ignition coil pack, the most efficient use of space which places the throttle valve low enough to easily connect to the stock throttle cable position.
0.1-9 Engine Carrier Bar: As sold by Rocky Mountain Westy.com Phone sales only at this time. Call and request "Engine Carrier Bar, Part# RMW-EC02." Unlike the T1 (Split Window) Bus, the target vehicle requires the use of an engine carrier to transfer most of the weight of the engine to the frame. This product was selected because it is built using controlled, jig based construction, outriggers bolt (not welded) into place at engine installation time, and holds the engine stable in three degrees of rotation, unlike any other solution on the market. (It is also the only non-custom solution available in North America at this time.)
0.1-10 Cooling Solution:
Dual 'Scirocco Style' VW 321-121-253AL radiators (525x322x34mm)
In engine compartment, installed inline, occluding access to left and right battery bays with inlet/outlets to the rear of the compartment. VW Stock thermo-switch holes in the radiators must be plugged, as VolksarU leverages the Subaru ECU for cooling fan control.
0.1-11 DIY Fabricated radiator frames, baffles and bulb gaskets.
Note: Some stock, stamped sheet-metal must be carefully removed from the engine compartment to enable an airtight fit of the radiators. If preserved, the pieces may be welded back in place in about 30 minutes for a return to the air-cooled design.
0.1-12 Fan Support:
0.1-13 Fans
280mm dual speed 250W/150W VW stock units part# 165-959-455AM. Fan control will PROVISIONALLY be by the Subaru ECU which is designed to control two fans (one circuit each) in a stock Subaru installation. Instead of one fan for each circuit, the ECU will treat the 150W circuit pair as the FAN2 circuit and the 250W circuit as FAN1. (The electrical design is being collaboratively designed with Jeff Robenolt of Wisconsin, a veteran of Subaru-to-VW wiring harness builds.)
Because the fans use dual phase power (circuit 1 powers the 150W motor windings, and circuit 2 doubles speed output by turning on the second winding 180° out of phase with the first. With both circuits in play, the speed is pretty extreme and power hungry. Multiply that by two fans (four circuits) and you're pulling about 40Amps, 20 per circuit. Because this 'unique' system is going to require substantial juice to be RDCL ready, it should use 10g stranded AWG copper wire, a 20A fuse per fan pair, and new fan motor connector housings, VW P/N 1H0-906-233.
280mm dual speed 250W/150W VW stock units part# 165-959-455AM. Fan control will PROVISIONALLY be by the Subaru ECU which is designed to control two fans (one circuit each) in a stock Subaru installation. Instead of one fan for each circuit, the ECU will treat the 150W circuit pair as the FAN2 circuit and the 250W circuit as FAN1. (The electrical design is being collaboratively designed with Jeff Robenolt of Wisconsin, a veteran of Subaru-to-VW wiring harness builds.)
Because the fans use dual phase power (circuit 1 powers the 150W motor windings, and circuit 2 doubles speed output by turning on the second winding 180° out of phase with the first. With both circuits in play, the speed is pretty extreme and power hungry. Multiply that by two fans (four circuits) and you're pulling about 40Amps, 20 per circuit. Because this 'unique' system is going to require substantial juice to be RDCL ready, it should use 10g stranded AWG copper wire, a 20A fuse per fan pair, and new fan motor connector housings, VW P/N 1H0-906-233.
0.1-14 Coolant Plumbing:
The primary cooling loop will use an as yet undefined variation of the Tom Shiels Concept5 cooling design which was developed for the liquid cooled VW Vanagon line. The primary cooling loop uses the Tom Shiels Thermostat Housing in conjunction with a Subaru Genuine Factory Thermostat.
The Coolant Expansion Tank #025 121 403B (and capped with the overflow pressure cap #025 121 321B) is fed by the coolant manifold auxiliary output, and returns to the coolant bypass intake above the main radiator return. This is a design that leaves out cab heat initially, adding it in later when the Tom Shiels thermostat adapter can be included. At that point the coolant aux output ia re-routed to the cab heater, which is then returned to the expansion tank and on to the thermostat adapter bypass. The mount for the Coolant expansion tank is from Rocky Mountain Westy, PN RMW-CBB
0.1.-15 Exhaust
The Exhaust system generally needs to be engineered from the manufacturer to work together as a unit. While many solutions have been generated for the Vanagon, no long term solution for the Bus can really be said to exist. The entire exhaust, from header to tailpipe must be supported by the engine, not by the body. The only non-custom solution available which is compatible with the T2b Bus is the the one from Rocky Mountain Westy. Their system is composed of:
- A Stainless Steel header (dual or single port exhaust) with O2 sensor bung
- An Exhaust Heat Shield System, which on the Bus would act primarily as a anchor point for the Exhaust Bracket.
- An Exhaust Bracket, which bolts to the heat shield and supports the far end of the exhaust system at the muffler.
This exhaust system supports many different 2 inch in/out catalytic converters w/O2 bung, and mufflers between 5-6 inches in diameter. There are a number of combinations to chose from, though I suggest the Magnaflow 53034 Universal Catalytic Converter and Magnaflow 13650 XL for a muffler. Connect the header, CAT & muffler together with Walker or Dynomax 32288 Butt Joint band clamps. You will also need to select your own slip-fit tailpipe, and unless you are using 'every part of the buffalo' from the Subaru donor vehicle, will need two O2 sensors. The Walker 250-23088 3-Wire Oxygen Sensor/OE connector is a practical replacement for the factory O2 sensor by DENSO.
0.1-16 Air Intake
The most ideal air intake would permit the use of a stock Subaru air filter box and air intake resonator, retaining the replaceable paper air filter commonly available for the Subaru vehicle which donated the engine. An easily adaptable alternative is the Acura air filter and housing.
This, of all sub-systems, is where it is most tempting to momentarily forget the #1 priority of the VolksarU design: Reliability. It doesn't seem like a big deal to just slap a K&N cone on the end and be done with it, but this is a terrible option for Reliability.
A cone style filter is not viable because they simply allow too much particulate matter past the filter and into the engine and are more prone to impaction when overwhelmed with dust or dirt. All but one cone filter solution is based on an open filter design, e.g. the filter is not enclosed and the air is not ducted to it. Only the K&N Apollo is a closed solution, and it disqualifies itself because it contains an oiled cone filter.
For a complete ISO 5011 empirical test between OEM paper filters and K & N style cone filters (washable) see Debunking the K & N Myth - Why OEM is Better. This is a detailed $15,000 evaluation by the Testand Company of Rhode Island on their quarter-million-dollar integrated qualification hardware. The results are surprising.
0.1-17 Tools
One of the essential elements of VolksarU is that anyone with a set of common power tools and a few inexpensive specialty tools can perform the fabrication of the radiator mounting. The materials, tools and fasteners are also inexpensive and commonly available.
I've included all of tools you'll need, and the costs involved for each, assuming that you don't have any of them. You might have a electric drill, but might not have a set of drill bits appropriate for drilling through steel. So all of the tools are defined. Vendors, Part numbers and prices are in the 0.1-18 Costs section.
You will require:
0.1-18 Auxiliary Hoses
There are a lot of hoses on the EJ22 engine, and they aren't all for coolant. Some are for vacuum signalling, some are for emission control, and some carry coolant to parts you wouldn't imagine would need them. (Coolant to the throttle valve assembly?!?) Sure. If its been below freezing (the metal of the engine is still below freezing) and ambient air is humid and just above freezing, now start. You're dragging cold, moist air into your freezing cold intake manifold very fast. What happens? It ices up and causes stalls and horrible performance. So there is a coolant tap right off the engine to supply heated coolant to the throttle valve body, making sure it is nice and warm, so no ice-ups. Little things like this make an enormous difference in daily drive-ability at the cost of a micro-dot of performance. Many hose are standard sizes but MEASURE FIRST before you assume and purchase blindly. If you want the pretty, pre-formed hose, you'll either be going to the dealership and ordering by part number, or you can buy a variety of preformed hoses and hope you chose right.
One hose that is an absolute must is the vacuum power brake line. It is 15/32 at the booster canister end by the master cylinder. Gates hose GAT 27233 is the perfect replacement for it, but measure how much you'll need first.
0.1-19 Costs
This, of all sub-systems, is where it is most tempting to momentarily forget the #1 priority of the VolksarU design: Reliability. It doesn't seem like a big deal to just slap a K&N cone on the end and be done with it, but this is a terrible option for Reliability.
A cone style filter is not viable because they simply allow too much particulate matter past the filter and into the engine and are more prone to impaction when overwhelmed with dust or dirt. All but one cone filter solution is based on an open filter design, e.g. the filter is not enclosed and the air is not ducted to it. Only the K&N Apollo is a closed solution, and it disqualifies itself because it contains an oiled cone filter.
For a complete ISO 5011 empirical test between OEM paper filters and K & N style cone filters (washable) see Debunking the K & N Myth - Why OEM is Better. This is a detailed $15,000 evaluation by the Testand Company of Rhode Island on their quarter-million-dollar integrated qualification hardware. The results are surprising.
0.1-17 Tools
One of the essential elements of VolksarU is that anyone with a set of common power tools and a few inexpensive specialty tools can perform the fabrication of the radiator mounting. The materials, tools and fasteners are also inexpensive and commonly available.
I've included all of tools you'll need, and the costs involved for each, assuming that you don't have any of them. You might have a electric drill, but might not have a set of drill bits appropriate for drilling through steel. So all of the tools are defined. Vendors, Part numbers and prices are in the 0.1-18 Costs section.
You will require:
- An Automatic Center Punch
- 8 or 10 inch flat bastard file
- 4-in-1 Aluminum Angle Square
- A 3/8" chuck Variable Speed reversing electric (not battery) drill
- An SAE (Standard) Nitride Coated Steel drill bit set
- A Variable Speed Jigsaw
- A Bosch T118A 3-5/8-in T-Shank High-Speed Steel Jigsaw Blades
- A 4-1/2" Angle Grinder
- A Grinding Disc Assortment (cut-off, flap wheel, grinding disc)
- A Threaded Insert Riveter Kit
- An SAE (Standard) Die & Tap kit
- Safety Glasses
- Work Gloves
0.1-18 Auxiliary Hoses
There are a lot of hoses on the EJ22 engine, and they aren't all for coolant. Some are for vacuum signalling, some are for emission control, and some carry coolant to parts you wouldn't imagine would need them. (Coolant to the throttle valve assembly?!?) Sure. If its been below freezing (the metal of the engine is still below freezing) and ambient air is humid and just above freezing, now start. You're dragging cold, moist air into your freezing cold intake manifold very fast. What happens? It ices up and causes stalls and horrible performance. So there is a coolant tap right off the engine to supply heated coolant to the throttle valve body, making sure it is nice and warm, so no ice-ups. Little things like this make an enormous difference in daily drive-ability at the cost of a micro-dot of performance. Many hose are standard sizes but MEASURE FIRST before you assume and purchase blindly. If you want the pretty, pre-formed hose, you'll either be going to the dealership and ordering by part number, or you can buy a variety of preformed hoses and hope you chose right.
One hose that is an absolute must is the vacuum power brake line. It is 15/32 at the booster canister end by the master cylinder. Gates hose GAT 27233 is the perfect replacement for it, but measure how much you'll need first.
0.1-19 Costs
Some costs are necessarily estimated, since the cost and availability will vary for sheet steel, donor vehicle and fan housings sourced from other hobbyists or a wrecking yard. I consider my costs to be slightly on the high side, since I got to practice buying what didn't work before I settled upon everything that DID work to produce this specification.
0.1-19A Components - Estimated Cost:$3938
| Product | Cost | Vendor |
|---|---|---|
| Donor Vehicle | ~$600 | Local Ads |
| Wiring harness Modification | $575 | Jeff Robenolt |
| OBD2 Interface Board | $65 | SmallCar.com |
| Vehicle Speed Sensor | $80 | RockyMountainWesty.com |
| Transmission Adapter | $520 | PN#OF-001 RockyMountainWesty.com |
| Starter Adapter | $80 | PN#WV-001 RockyMountainWesty.com |
| Starter (Bosch SR0408X) or those compatible with VW PN# 02A-911-023RX 02A-911-024D 02A-911-023R |
~$70-150 | Widely available |
| Throttle Valve Reverser | $150 | RockyMountainWesty.com |
| Coolant bottle bracket | $25 | RockyMountainWesty.com |
| Expansion tank 025121403B | $27 | RockyMountainWesty.com |
| Expansion tank cap 025121321B | $10 | RockyMountainWesty.com |
| Engine Carrier Bar | $400 | PN#RMW-EC02 RockyMountainWesty.com |
| Exhaust Header Kit | $590 | PN#RMW-SSESP-4 RockyMountainWesty.com |
| Exhaust Heat Shield and Muffler Support | $200 | PN#RMW-HS22 RockyMountainWesty.com |
| Muffler Support Bracket | $40 | PN#RMW-EXB RockyMountainWesty.com |
| Stainless Steel Tailpipe Kit | $50 | PN#RMW-TLP RockyMountainWesty.com |
| (2) Walker 250-23088 O2 sensors | $32 each | Widely Available |
| Stainless Steel Tailpipe Kit | $50 | PN#RMW-TLP RockyMountainWesty.com |
| Magnaflow 53034 Catalytic Converter |
$77-150 | Widely Available |
| Magnaflow 13650 XL Muffler |
$65-150 | Widely Available |
| (2) VW321-121-253ALradiator | $60 each | Widely available aftermarket by Behr, Nissens |
| Fan Cowl Assembly | $40-90 | Used parts only |
| (2) VW 280mm 250W/150W Fans VW#: 165-959-455AM |
$50 | PierSide Parts |
| Thermostat Housing | $67 | Tom Shiels |
0.1-19B Products - Estimated Cost:$100
| Product | Cost | Vendor |
|---|---|---|
| (2) 2x4 foot 12 gauge cold rolled steel sheet | ~$25 each | Available to the consumer via most steel retailers |
| (3) .75W x .75H x 36L inches hot rolled square steel tube | $27each | The Hillman Group Model #: 11738 |
| (10) 1/4-20 x 1-1/4-in SAE Machine Screws | $3 | The Hillman Group Model #: 883588 |
| (10) 1/4-20 x 3/4-in SAE Machine Screws | $3 | |
| (10) #8-32 x 3/4-in SAE Machine Screws & Nuts | $1.24 | Blue Hawk Model #:605405 |
| 3M/Dynatron 550 12 oz. auto seam sealer | $15 | Autozone/Advance Autoparts |
0.1-19C Tools - Estimated Cost:$136
| Product | Cost | Vendor |
|---|---|---|
| An Automatic Center Punch | $3 | Harbor Freight Item#621 |
| 8 or 10 inch flat bastard file | $3 | Harbor Freight Item#46065 |
| 4-in-1 Aluminum Angle Square | $2 | Harbor Freight Item#7718 |
| A 3/8" chuck Variable Speed reversing electric (not battery) drill | $19 | Harbor Freight Item#60614 |
| An SAE (Standard) Nitride Coated Steel drill bit set | $20 | Harbor Freight Item#5889 |
| A Variable Speed Jigsaw | $22 | Harbor Freight Item#69436 |
| Bosch T118A 3-5/8-in T-Shank High-Speed Steel Jigsaw Blades | $7 | Home Depot, Amazon |
| A 4-1/2" Angle Grinder | $15 | Harbor Freight Item#69645 |
| A Grinding Disc Assortment (cut-off, flap wheel, grinding disc) | $9 | Harbor Freight Item#47572 |
| A Threaded Insert Riveter Kit | $18 | Harbor Freight Item#1210 |
| An SAE (Standard)Die & Tap kit | $10 | Harbor Freight Item#69679 |
| Safety Glasses | $2 | Harbor Freight Item#43946 |
| Work Gloves | $6 | Harbor Freight Item#60447 |
1 comment:
Keep up the good work Marshall. We are all enjoying the progress.
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