VW Syncro Westfalia - Build Log with Pics

[a1fa]

Let me know if you need any parts. I am going to Poland tonight. I ordered 3 horn contact rings for $15/pop, versus $55 from robWesty.

[Hodakaguy]

Originally Posted by a1fa

Let me know if you need any parts. I am going to Poland tonight. I ordered 3 horn contact rings for $15/pop, versus $55 from robWesty.

Will do! Thanks!!

Hodakaguy

[Hodakaguy]

Ok...progress is being made...slow....but being made.

Time to install the oil pan, sure is nice having the engine on a stand!




Pan is off. Here's a shot of the OEM unit next to the RMW shortened pan.




A shot of the shortened oil pick up next to the OEM unit.






Here's a close up of the pick up tubes. Notice the stock unit has three points that stick up around the pick up area, if the pan gets dented/flattened these will make sure that there is still sufficient room for oil to make it to the pickup.




The RMW pan is very high quality and has a thick bottom on it, it would be hard to dent it hard enough to close off the oil pick up.....but I thought I would add a little extra insurance just in case. Here I just TIG welded a couple stainless steel rods to the bottom of the pickup. If the pan gets smashed in it should keep a sufficient gap between the pickup and pan...assuring a healthy oil supply to the engine. :-)






Shortened pick up tube and new O-ring installed.




At this point I ran into a little problem. The shortened pan wouldn't fit. The baffle that is welded into the pan is interfering with the baffle that is bolted inside the engine, keeping the oil pan from sitting all the way down onto the block. A email and call to RMW verified that the 06 pan can't be shortened so they supply 04 down pans, I will need to trim the engine side baffle a little to get the clearance needed to install the pan on 06 engine. Should be a easy fix.

On a side note the oil return tube is missing from the shortened pan, RMW said they haven't had any issues with this setup and I'm sure it will be fine but my OCD is kicking in so I will contact RMW about it and see if they have a unit with the tube still in place. I might end up welding in the return tube from the OEM pan if a replacement isn't available.

A shot of the contact points with the shortened pan and 06 engine.






With the oil pan install delayed a bit I turned my attention to re-installing the intake system. Looking like a engine again :-). I will leave the AC Compressor and Alternator off the engine until I verify the shortened pan will work, just in case I need to install the OEM dipstick again.




Now it's time to remove the stock engine so I can start prep for the Subaru installation. Here Mike is disconnecting the shift linkage before we drop the engine.




Engine ready to lower.




Separated from the trans.




Almost out!




Out!








Now to remove the wiring harness, trim the firewall, drop the tank and clean it.....lots more to come!



Hodakaguy

[a1fa]

ah, the point of no return.. :) i remember those days..

[TEXASYETI]

I see you have no fear on that gorgeous, new driveway!

Keep it coming, this is a sweet build!

[panamapassage]

Absolutely splendid Syncro - my next one will be a 1991 too.

Good call on the fuel line.

Here's what happened to mine:

http://www.expeditionportal.com/vehi...st-friend.html

[Hodakaguy]

Originally Posted by TEXASYETI

I see you have no fear on that gorgeous, new driveway!

Keep it coming, this is a sweet build!

That's what I installed it for

Hodakaguy

[Hodakaguy]

Originally Posted by panamapassage

Absolutely splendid Syncro - my next one will be a 1991 too.

Good call on the fuel line.

Here's what happened to mine:

http://www.expeditionportal.com/vehi...st-friend.html

Man....that sucks! I've read sooooo many vanagon fire threads....all fuel lines must be changed! The stock engine/fuel rail setup is pretty pathetic at best, terrible design. There will be a lot less coolant and fuel lines with the subaru installed.

That was a nice looking Syncro!, sorry for your loss on it.

Hodakaguy

[Hodakaguy]

A little progress after work tonight. Removed the wiring harness and ECU.




Starting to get quite a pile of parts in the garage.




Decided to modify the engine baffle plate to get the shortened pan to bolt up correctly. The baffle in the 06 engines needs to be trimmed along the red line to clear the baffle in the earlier oil pan.




Here the baffle has been trimmed to fit.






The sections removed from the baffle.






And a picture of the oil pan so you can see why it need to be trimmed.




The extra clearance and stronger pan will be a great benefit.





I still need to verify proper clearance on the oil pick up and seal/bolt down the pan. Lots more to go!


Hodakaguy

[jgrady1982]

I love this thread!

[Hodakaguy]

Minor work done today. Trans removed :-)








Now that it's out of the bus I can clean it up, free the stuck diff lock actuator, clean lube the cross shaft, remove the starter and modify the diff actuator bracket to take the TDI starter.

Down to the car wash to clean the trans....but first a quick stop at Mikes to install the engine in his 67.




A couple cans of Gunk and we hang around for a bit and wait for it to do its magic.



Before...




And after.....There is still undercoating on the trans but it looks a lot better. I've give it some hand cleaning at home.






Next up to remove the coolant lines/hoses and remove the fuel tank.

Hodakaguy

[rider1150gsadv]

Great rebuild !!

My neighbor has a Westy and has had fuel line issues too, complete with fuel smelling up the 'hood . So far he's been on top of it, but a Subie conversion is on his short list as well.

[Hodakaguy]

Little more progress today.

Ready to get started. Going to remove the cooling lines first, then the fuel tank.

Nice clean cardboard to start with :-)




Removing the snap ties and two hose clamps that hold the plastic engine coolant lines and heater core lines in place.




Coolant lines removed from the bus.




The plastic lines are actually in great cond, the undercoating has protected them well and they are even still white in color under the coating. I will be replacing these with Stainless Steel lines when re-assembly starts.




Coolant lines out of the way.




With the coolant lines removed I can trim the firewall to accommodate the Subaru coolant lines. The firewall needs to be trimmed along the black line.




Quick work with the cut off wheel. The edge will be painted and finished off with a piece of molding.






Fuel tank straps and stub axle removed.




The straps are in pretty decent shape. I will sand blast and powder coat them before re-assembly.




Draining the fuel tank...I had ran it down pretty good before parking it and had only 3 gallons or so to drain. I used a piece of hose to drain it into the pan, wanted direct contact (bonding) with the hose and the pan so no static electricity would be developed.




I will remove the suspension on each side to install new bearings, seals, springs, shocks and powder coat all components before re-assembly. As long as the engine and trans are out of the bus now seems like a good time to do the work since I can easily work on the back side of the suspension. It's getting hot out today (close to 100 deg) so I'll stop outside work at this point today.

Bus on jack stands and tire removed.




Time to get a little inside work done. Cleaned on the trans a little and removed the cross shaft. I will replace the input seal before re-installing the trans.




Cross shaft is in good cond, the plastic bushing has a crack in it so I will try and locate one before re-assembly.






Started work on the diff lock actuator. The shaft is free and the actuator is functioning fine. I will clean/lube everything up and before installing the trans.




We'll I'm done for the day. More progress soon.

Hodakaguy

[Hodakaguy]

Originally Posted by rider1150gsadv

Great rebuild !!

My neighbor has a Westy and has had fuel line issues too, complete with fuel smelling up the 'hood . So far he's been on top of it, but a Subie conversion is on his short list as well.

Yeah the reliability of the Subaru will make the setup a lot more enjoyable

Hodakaguy

[Sniper X]

How much more HP and TQ does the Subaru motor have over the stock motor?