Club 80-90 Forums

Good progress today

Engine and box bolted together and now in situ on floor under the van between the unconnected driveshafts

- as soon as gearbox mount arrives - hopefully tomorrow it'll be bolted up to the van

ECU's all attached to the bulkhead under the seat

and while the tank is off lots of hammerite and waxoyl ....to all the bits we can't usually see.

tomorrow ......will be putting conduit on the harness/ bolting up the engine and box to the van - fuel pump and front ext loom and speed sensor /engine check light ... maybe mount the battery behind rear OS light

Im on Fire !

(not literally.... of course)

Its all happening quickly now

ECU's and relays/etc - all nicely mounted and bolted up this morning

gearbox bracket arrived from Multisi - thanks !

More brackets painted and lots of hammerite and hot waxyol splashed on anything and everything,

Speedo out and speed sensor installed - and front loom extension wired up and connected

Old throttle cable removed

Proper sound deadening material being cut for engine bay side of bulkhead - which inc chassis and panels has been treated with hammerite and waxyol.

All original pipes, tubes, rods and cables front to back cleaned, treated, reattached where req to chassis properly

Conduit put on harness - a very satisfying job, comes ready cut with the kit - amazing attention to detail from RJES .

wiring for fuel pump connected...

Just tp add I'm not usually spending a whole day per post, most days its a few hrs in the morning or afternoon so install time isn't as long as it might seem..

looking forward to more progress tomorrow

plan to install soundproofing, throttle cable - refit fuel tank (again !!!) - perhaps bolt engine in situ...

We will see


Best


Matt

Wow! Thats very good progress Matt, well done.

Cooling fan (original 2 speed) wired in to RJES extension loom .....
note, on early 1.6 CS red wire to fan = hi speed - red with black trace wire = low speed and brown wire = Earth

Soundproofing installed on engine bay side of bulkhead

Throttle cable removed and replaced with new RJES kit

Engine bolted up and in the van on the cradle and gearbox mount

... sorted wiring on the cooling fan, took gearshift rod off to adapt with the RJES kit, located battery behind rear light by cutting up and using bottom tray of old battery shelf so as to use the clamp and brace

Lots planned for tomorrow inc fitting a new radiator ...

so pleased I got one "in stock" when ECP had them on special offer a couple of years ago for a silly low price - about £30/40 quid iirc

Thanks again for all the tips and replies to get me this far

Nice to feel the engine is actually in the van now -

Best

Matt

Since last post

Throttle cable kit (rjes) - on... but inner still to insert and connect to pedal

Sorting the pipes - what goes where and thanks to others for guidance received to date

wiring - VW to Subaru not quite matching what was expected... early diesels are not same as later for colours and some connections it seems - work in progress - starter motor us so couldn't spin motor over today as planned

next few sessions will be finalising fuel, filler and cooling circuits ... reassembling interior and dashboard instruments and install rev counter

Decided against popping down to Brighton Breeze - maybe should have to pick brains of any subaru t25's but sadly for visitors the weather is pants -

Saw loads - and i mean LOADS of splittys in a convoy at 9am as I was leaving brighton this morning

This pm cracked on with improved routing of heater supply and return pipes and re routed throttle cable - connected up Brake servo to inlet manifold

- fitted rjes coolant by pass manifold on heater pipes - posted a q in mechanical section here about which side of heater matrix the VW heater control valve ought to be - RJES diagram shows it on the return pipe but I think its on the supply side on my van...

Dont suppose it matters too much - as long as its after the RJES (or does it ?)

Nice to tick a few jobs off the list - now for telly n tea

Hope to be turning the key tomorrow,

Had to get a new starter motor today , one off the engine was dead - £135- ouch - didn't see that coming

Wiring all starting to make sense, and tomorrow finalising the connections before hopefully.... picking up some petrol to put in the tank


Fingers x'ed

Matt

Good luck!

Sent from my BBB100-2 using Tapatalk

Well done Matt, fingers crossed for a good day today for you.



John

Yes


Tentative run round the block (no exhaust) - an amazing difference even at half throttle

Lots of finalising ....and tidying up today, but Im chuffed to bits ...

The diesel to petrol conversion threw up a few challenges, particularly with wiring in the starter and sensor systems but all sorted now

A very big thank you to everyone here who has helped with parts , advice and encouragement here

I will post a fuller summary and costs once I have tidied up the loose ends

Matt

Well done Matt, I hope that you weren't driving around Brighton at 2-30 in the morning with no exhaust, although after all that work I probably wouldn't be able to stop myself

Nice one Matt! Well done

Thanks...

and thanks again to everyone who took an interest, gave advice, and supplied me with some bits I needed such as gearbox mount / clutch mount from a petrol ( very cheaply so thanks thrice - ly for that too )

can't really get out n about till my mate had made my exhaust up- ....

Meantime lots of nice relaxing jobs to do -

Today was final routing for loom before I wrap it - refit carpets , dashboard, new sparky plugs fuse box etc etc

Tomorrow may fit my "fancy pants" rev counter.

Spreadsheet of final costs to be published soon (well, as soon as I can bear to add it all up... )

Best

Matt

Pictures please