2000 Subaru 2.5 litre SOHC Engine Installation
There are several compelling reasons to replace the aging 2.1 litre Waterboxer engine that came in the Volkswagen Vanagon.
The engine is an ancient design with direct links to the early air cooled Volkswagen engines of the forties. Consequently the ancillary systems from the fuel injection to the water-cooled heads are obviously afterthoughts.
It has an inefficient, low compression, 2 valve push rod layout and an unfortunate set of rubber gaskets to keep the coolant in the heads. The fuel injection hoses are festooned around the engine and have an unfortunate habit of dripping gasoline on to the hot exhaust and setting vans on fire.
There's also the lack of power...
Horsepower comparison: WBX vs Suby 2.2 & 2.5
Torque comparison: WBX vs Suby 2.2 & 2.5
The beautiful Outfront Motorsports adapter plate
Outfront Motorsports monolithic flywheel
New German Luk clutch and cover plate
5 speed transaxle mated to the new Subaru motor
5 speed ACW1411 transaxle with .70 5th gear and Positrac differential
The new 2.5 litre SOHC Subaru motor looks right at home in the van.
Subaru air filter assembly fits behind the left tail light
The coolant overflow bottle fits in behind the right tail light
Heat-bronzed stainless steel header
Tubes and hoses from below
The whole VW/Subaru throttle cable interface - not elegant but its safe and I get full travel
Crosby clips positioned to use factory cable ends
as safety backups in case of slippage
Angle iron mount to move Vanagon throttle cable to the right
Angle iron mount for the firewall end of the Subaru throttle cable
Stainless J-pipe leading to original cat and muffler
Dixie smelling the wisteria
I just fired up the new Subaru engine in Dixie and its running very well.
With the new Posi-trac differential I can spin both rear tires off the lights in the wet!
Update
Since this was first posted I have replaced the very tall .70 5th gear with a .77 which is
a better match for the 4.57 R&P and has eliminated the yawning chasm between 4th and 5th gears.
The van has performed very well in temperatures from 45 to 99 degrees F. and from sea level
to Washington Pass at 5477 feet.
I love my van!
Thanks to:
- Tom Shiels for the beautifully made wiring harness and the expert advice
- Outfront Motorsports for the adapter plate, flywheel & shortened oil pan & pickup
- Gary Zink Transaxles
- Vancouver Transmission for the clutch
- Brent Weide for the very informative website
- Gerry Shuttleworth for the 5 speed transaxle
- Dan Fleming for the VSS
- Smallcar Motors for the header & the engine mount
- Cal for the use of his garage