1981 Aircooled Westy to Subaru EJ25 Conversion

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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dollytony » 31 May 2015, 18:32

Had a bit of a problem after I fitted the gear linkage as I could not select reverse gear, even though I had mark the centre joint & refitted in the exact same place. So had to follow the wiki but ended up using a 27mm spacer which finally worked.

So went for a spin & I must say first impressions are great, not really opened it up yet but plenty of power & very lively, the exhaust is a little louder than expected but ok.

One problem I have is the revs seem to stay high between gear changes, I have checked the throttle cable & it is not sticking, any ideas? Same when I come to a stop & dip the clutch the revs take a while to die down.
Last edited by Dollytony on 31 May 2015, 22:32, edited 1 time in total.
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby silverbullet » 31 May 2015, 18:47

Could be a fault code that needs clearing or it needs to re-learn all the fuel and ignition trimming values. This can take a couple of hours of varied driving.
A persistant hanging idle is one of the reasons why I removed the EJ22 in the end. Couldn't cure it, the other reason was a full-throttle misfire.
Great engine but the looms aren't up to much when they get old, the engine side threaded between the block and inlet manifold does suffer from heat damage.
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dollytony » 31 May 2015, 20:33

Thanks for the reply SB hopefully it will settle down then, the donor car had very low mileage so loom should be ok.
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby silverbullet » 31 May 2015, 20:53

No problem. Ecu re-learning and loom degeneration info is via Impreza engine builders that I know.
The trick is to get a good drive done in one hit: around town, motorway, steep hills, gentle B roads, the lot.
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby syncroandy » 31 May 2015, 22:44

Hi Tony, glad to hear it's on the road. Regarding your comment about the engine speed, try grounding the NPS wire (white/black) in the spare bundle near the ECU. Yours is the first 2000> auto I've done, on the manual ECU's that wire is left floating, but I'm not surprised to hear the auto behaves differently. SB is quite right about the ECU learning though, it is sometimes noticable when switching between LPG and petrol. Subaru loom was in very good nick as usual.
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dollytony » 01 Jun 2015, 06:48

Will give it a try, is that wire labelled, thanks Andy.

Only been on a short spin to the petrol station and back as still trying to get the cooling system completely full which I am pretty sure it is now, so will take it for a longer drive later this week
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dollytony » 28 Jun 2015, 12:27

Finally got the cooling system sorted, turned out that the thermostat was stuck closed. Got a new one fitted and now all good. Still got the hanging idle problem anyone got any ideas?

Also still after a tow bar if anyone has one going spare :ok
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dollytony » 06 Aug 2015, 13:13

Van is running well now, hanging idle a lot better now the ECU thinks the car is manual & not automatic (thanks Syncroandy for sorting that out).

Just returned from a 2000 mile/ 2 week road trip around Europe, taking in France, Switzerland, across the Alps to Italy, then back through Austria, Germany, France (again), Luxembourg (cheap fuel) & Belgium.

No problems, just got a bit hot on the motorway in the +30 degree heat cruising at 75, so will invest in a thicker radiator for next time.

Haven't worked out the fuel economy yet, but getting about 200-250 miles between fill ups so I think that is about mid 20's.

All in all really pleased with the conversion. :ok
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby silverbullet » 06 Aug 2015, 21:20

Glad you sorted the auto/manual wiring glitch.
250 miles from a 70 litre tank doesnt sound very good at all though... thats more like 16 or 17mpg!
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dollytony » 06 Aug 2015, 22:29

I didn't trust the gauge & also didn't know the tank capacity each 'fill up' was about 40 - 45 litres, I thought the tank was 50 litres as I filled up when he needle was in the red, but I must have still had 5 gallons left!
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dazco » 09 Aug 2015, 10:21

Just read all the thread youve done a great job , even better concidering it was an air cooled . Would love to do the subaru conversion on mine as and when the original lump dies but doubt if I would be able to manage it . Love the vid as well .
Great job :ok
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dollytony » 10 Aug 2015, 17:14

Thanks Dazco, glad you enjoyed the thread.

Here's a pic of the van up in the clouds at the top of the Alps between Switzerland & Italy.

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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby silverbullet » 10 Aug 2015, 17:42

Nice photo. Guess it delivers the goods then!
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby pionte » 11 Aug 2015, 18:57

Great to see it all finished and you using it to the max , I watched your video again, and it bears remembering just how much work you have done 8)

Top job, mine is all done now as well, but as it was already a wasserboxer there was no where near as much work as you have done . :ok
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Re: 1981 Aircooled Westy to Subaru EJ25 Conversion

Postby Dollytony » 11 Aug 2015, 19:27

Thanks Martin, glad yours is all finished, what do think of tge extra power?

We certainly went for it with our 1st camping trip to Europe.

We drove down to Lake Garda, but it wasn't the 1st time the van had been there as on the way down my daughter dropped her phone down the side of the seat, whilst I was fishing it out I retrieved a parking ticket from Lake Garda dated 1999!
Very Spooky.
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