Syncaroo (Subaru into Syncro)

[ericos_bob]

Yep the rjes engine mount does not clear the smallcar sump. I found out the hard way . The smallcar stainless exhaust won't clear the engine mount either. Don't know if rjes exhaust and sump will fit with smallcar engine mount but I'd def go either all rjes or all smallcar parts on those 3 items to be sure. I'm running an rjes bellhousing with no problems.

[syncroandy]

Agreed, I'm using SC exhaust, engine bracket and sump, and everything else is RJES. It all fits together fine, and results in a neat 'factory-like' look with no odd angle-iron brackets. I much prefer the SC muffler mount system which bolts simply and strongly to the back of the engine mount. The only significant task left over is to complete modding the under-run bars and re-fit.

The SC header (which is nicely designed and made for maximum clearance) did interfere slightly with the bellhousing, requiring a slight clearance to be made on the bellhousing with an angle-grinder. The only grumble I have about he SC stuff is the header developed a few cracks last winter, requiring welding, and the finish on the engine mount was quite poor as supplied and needed to be re-done.

[rollercoaster]

Yep the rjes engine mount does not clear the smallcar sump. I found out the hard way . The smallcar stainless exhaust won't clear the engine mount either. Don't know if rjes exhaust and sump will fit with smallcar engine mount but I'd def go either all rjes or all smallcar parts on those 3 items to be sure. I'm running an rjes bellhousing with no problems.

Thanks again for the input..

Well I'm struggling to keep up now, but it might be good to be more specific about what engines and sumps and vehicles we are talking about for reference.
Am I missing something or did Dr Rex say his SmallCar sump fitted and Ericos Bob said his didn't?
There must be different sumps available or other factors involved, I was relieved to think it was all simple but now its just confusing again.

[doctor.rex]

Yes, on my syncro conversion I am using RJES engine bar, bell housing and exhaust and a small car sump. Everything fits (though I had to fabricate extra mounts for the exhaust - syncroandy is right, 2 angle iron brackets!) except the engine protection bars. If you need pictures let me know
cheers Mike

[sonic23]

Unless Richard has got his sump sorted yet, then I'm going mostly with Andys solution, though with my own additions:
DOHC 2.5 98 source engine with 100k (getting a top end rebuild)
RJES Bell housing. (still haven't decided to go NA/Turbo.....but from Andy's experience - maybe Turbo due to van weight)
RJES loom mods + front haness extension
RJES coolant reversal
RJES accelerator cable
RJES fuel pump
RJES VSS
RJES clutch kit - using vw friction plate
Small Car shortend stainless sump
Small Car engine mount adapter
Small Car stainless header + J pipe, and silencer mounts
Small Car flex dip stick
Small Car syncro protection bar extension

[syncroandy]

Perhaps I should add that I did have to cut a piece out of the panel between the engine and the fuel tank, to permit clearance for the Subaru inlet duct I'm using. I think the RJES custom rubber inlet duct may avoid having to do this. Yes, from my experience a heavier T3 (eg. Syncro camper) with a 2.5 may need a turbo clutch, mine started to slip after ~8 months and I changed to the turbo setup ~14 months after the original install. It's noticably heavier to operate but quite tolerable (to me anyway).

Also, its worth replacing all the engine seals and gaskets while doing the install, though my motor was only 53k when installed, its needed a head and water pump gasket since.

[stubbie]

Andy had his electronics mounted inside the van in a neat little box on the passenger side above the rear lamp cluster.

Be very careful with this set up, mine was done this way and the water got in through the loom entry hole and destroyed the ECU and this I'm finding out is an expensive business. Anyone want to buy a really nice rust free Syncro with a nice engine but is a non runner...

[syncroandy]

Be very careful with this set up, mine was done this way and the water got in through the loom entry hole and destroyed the ECU and this I'm finding out is an expensive business. Anyone want to buy a really nice rust free Syncro with a nice engine but is a non runner...

Misunderstanding I think, my ECU is inside the van and short of the whole vehicle being submerged there's no risk of water ingress:

[ericos_bob]

Lol if andy ends up flooding his ecu up there you can be sure mine is going to flood much sooner being mounted down here.

Kind of hoping my soon to be syncro camper never ends up with with more than 10cms of water in the back that would make an awful mess of the interior.
My bad on the sump doctor rex is right it actually fits real neat with the rjes engine bar from memory don't know what I was thinking when I said it doesn't fit. The smallcar stainless exhaust header definitely cannot be worked around to fit with the rjes bar though.

Perhaps I should add that I did have to cut a piece out of the panel between the engine and the fuel tank, to permit clearance for the Subaru inlet duct I'm using

I was told to do this also with the 2.2 conversion but it seems to clear (just) without any cutting needed. My conversion, however is a 92 2.2 subi engine to clarify

Andy, do you have any photos of your engine bay. Interesting to see how you connected the snorkel. Did you reverse and attach the snorkel to the opposite side of your syncro and use the subi airbox? The only things that i found that couldn't be bought as a bolt on fix was and air intake set up and seems a lot of people have not connected the snorkel. How do the sensors do in water crossings. I always wondered what would happen if the camshaft sensor or crank sensors were emerged in water. Some sensors are pretty low down which is a worry

[syncroandy]

That's really neat, using the factory WBX ECU bracket. My LPG tank sits across there now so the access to fit the Subaru and LPG ECU's was insufficient, otherwise I'd have been tempted. I had an oblong space under the bed platform so I just used that for the electrics.

Regarding air inlet, no I've not hooked up the original snorkel, though it should be possible to relocate it to the left side and connect to it. I'm using the original Subaru airbox, and the inlet is tucked away up above the L/H rear light cluster. It's a reasonable height up, and should get nice fresh air which comes in the L/H rear air vent. Pics below.

I've also put up a couple of pics of the Smallcar sump. You can see how the SC exhaust, engine mount and sump fit together nicely. You can just see how the muffler bracket bolts to the back of the engine mounting. Regarding the senders, they all seem well enough sealed to me, if they can survive pressure washing the should be OK for occasional wading.

[rollercoaster]

Thanks
All the pictures and words are really helpful,
Syncaroo is running and will be at the exhaust shop on Thursday, then an MOT and shakedown miles and tighten up.
Simon sent me a picture yesterday, I have given up trying to learn how to post it, but here is a link to it on flickr:
http://www.flickr.com/photos/interplay/5260021615/
He reckons I should be driving it myself very soon, oooh I am salivating at the thought of smooth reliable power.
There will still be the modified sump and the engine protection to sort out myself, so dont expect this thread to fade fast..

[spannerboy]

Well it is all mot'd and 150 miles into to its maiden voyage,all has been well so far,it has been enormous fun today as we have a snow covered field outside my workshop This van has been nemesis and fought me every step of the way,but it is all there now,just need to do a last checkover on it and clean everything up then it will ready for tim to take away.I will post up some pics of it in the snow tomorrow.

I would like to say a big thank you to Richard at RJES,Aidan and tim for his patience.

[silverbullet]

Yes your field is really good fun in the snow, Simon
Allroad behaving itself?

[spannerboy]

Merry christmas Tim.

[rollercoaster]

The Syncaroo has cracked about a 1000 miles and is happily parked outside home,
driving it is pure joy, the throttle is taking some getting used to, (grin)
the exhaust note is also quite special, its all transformed!

What can I say?
Thankyou to everyone for all the support, and especially Simon Spannerboy,
its true, his attention to detail and love of his work really shines.

And this is not the end of the subject its a beginning,
There are some important things to take care of:

A sump, the only option I can make sense of is the Small Car Aluminium sump,
(last chance for other suggestions welcome)

A Tacho, dont quite know why but the sender doesn't fire up the original one.

Put the engine protection bars back on with whatever mods are needed.

Make some attempts at waterproofing, like maybe look for a snorkel for the other side.
And whatever else will help it get through the deep puddles.

A set of AT wheels and tyres, The Grabbers are ok but a bit varied and no spare.
I have seen some great mud pluggers that I would love to get a set of wheels for too,
not really roadies at all but just what I need for "tractor" work occasionally..

Also I have a potential issue with the "speed sensor" which is not fitted and comes up as an error code,
which means that its possible that the engine may stall when coming back to tickover.
Simon is fairly sure I will be able to manage without one, any other thoughts?

Purists will be happy that I have relaxed the idea of popping the roof, but I would at least like a R+R seat,
and the aircon stuff is now redundant as the Subi doesnt have one and I am all for the economy,
as well as trying to claw back some money out of this project!

Well, I'm off to spin it about a bit more and take in a sunset on the coast,
Yippeeeee....