EJ20 donor version - diagnostics and BUILD

[slowcoach]

Just to be clear, I understood the brief to be something along the lines of "can you mackle me up an exhaust that will get me to the nearest custom exhaust place?", that being about 30 miles I thought the old bike can would just about do the job. It was never intended to go to f$%&ing Edinburgh !!!

hooo! yes quite right andrew its performed beyond its brief alright! (which was as you say, was to get me home i also went to west wales for a festival this weekend (last weekend was edinburgh, keep up!) ... bad idea i know, but it had been booked with the boss! its battened down further now with rivets and more straps.

Dai is coming up with an exhaust for all EJs which should fit rjes engine bar, plus small car's setup. Ive got that ordered for the end of this month, so im looking forward to a not so obnoxious sounding bus

I need to fix up my broken dash pod, make some bracket repairs for it and either get a secondary tacho pod thing (not so keen) or get an oem tach to fit into mine. I can use the tach feed from the subaru loom to drive the vw tach (with a signal wave adapter or something). Does anyone know for sure what vw oem tach i can insert into my 84 dash pod (which has no clock - just temp and fuel guage on the right hand dial) ?

[slowcoach]

Ive found a great doc explaining all the different dash clusters, and how to swap what. Its US based though so perhaps a little diofferent as far as versions.

http://www.oldvolkshome.com/late_van_cl ... nstall.pdf

Interesting is that fitting a late model cluster (post 85) into an early van has the multi plug wires in very different positions, and so id need to re arrange them to match my early wiring. its all listed in that doc though.

[slowcoach]

Little update. Immobiliser in the bench seat kick board. I'll probably put a collar round it to protect it further, but it's quite tucked in by the extinguisher [GRINNING FACE WITH SMILING EYES]

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[slowcoach]

So ive got a new cluster on the way, and now have a real exhaust fitted which is a huge improvement to noise and smoothness of the engine. (that thread is here: https://club8090.co.uk/forum/viewtopic.php?f=12&t=154245.

now that the roar of the old exhaust has gone i can now hear another noise...! the intake cone! now i realise what people meant by this. its like a droning vibration, can be heard, and even felt - the rear d pillar corner buzzes with the reverberations coming up the vent. its not ruining my day, but ill probably put some sound deadening stuff on the inside of the vent cavity. last weekend i had the door cards off and stuck butyl flashing (not bitumen) onto the panels and its helped interior noise somewhat. i used this from screwfix:
http://www.screwfix.com/p/sika-multisea ... -10m/38892



Photo taken before.. forgot to take one after! Hmm

Ive still got the forester air box, but it looks a a longer, narrower shaped one than the more square ones ive seen fitted behind the light cluster. One day i might see if itll fit somehow.

Next job is to swap the cluster over, once ive checked it all works. onwards!

[slowcoach]

ironing out some things ive always had a knock sensor error code, which i believed was being cause by not having the oxygen sensor connected. turns out its the knock sensor

Ran fine though.

the fitted one had a resistance of 5 Mega ohms once read 'on the bench', well out of the spec which is 4k-7k ohms. so the new genuine one from import car parts is here now, and has a 5k ohm reading which is correct. will fit tonight in the dark with torches.. already missing the evening light

Old one


New one now fitted and codes cleared (battery disconnected over night). Will see this weekend. Fingers crossed !

[slowcoach]

New one fitted and engine happy no lights. Will track the mpg now, hopefully will get over 26 now.