Ordering parts to replace

I made the parts order:

• timing belt


• timing gear sprocket


• cylinder head gaskets


• valve cover gaskets


• valve stem seals


• front/back crankshaft seals


• camshaft seals and o-rings


• water pump, gasket and seal


• thermostat and gasket


• oil pump seal


• oil inlet tube seal


• timing gear sprocket


• intake/exhaust manifold gaskets

The price of these items add up to nearly 1/3 the price I paid for the engine itself. However, it's pretty simple to do the work right now when the engine is sitting on the workbench. However, once the engine is installed, doing the same work would require a heck of a lot more time and energy. Therefore, it's a matter of "pay me now or pay me later" I'd rather do the work now when it's easier.

Removing even more components

The following evenings, I removed the cylinder heads, oil pan, water pump, oil pump, and front timing gear assembly. The engine looks really clean...no ridge at the top of the cylinder bore, and minimal carbon on the pistons or cylinder heads.

I probably could have done without removing the cylinder heads, but since I have never heard the engine run, I figured it was worth the effort to ensure that the combustion chambers are sealed up tight.

There wasn't much grime on the cylinder heads, but I did clean them with water-based degreaser and put some into the intake and exhaust ports. To clean that off, I went a few blocks to the local car wash, and used the high pressure rinse setting to remove all of the grime and degreaser. Then, I brought the cylinder heads home and used compressed air to dry them. I then sprayed the sensitive areas [valve assembly, combustion chambers with WD-40 to displace any residual moisture.

Another job I need to do [this week] is remove the valves, both so I can check the valves for fit and wear, and also to replace the rubber valve seals. Even without a lot of wear on the engine, the [rubbger] valve seals harden and cause a little oil to drain into the combustion chamber, causing a little puff of smoke when the engine is started.



A few years ago, a similar puff of smoke on startup kept me from being able to register my Mazda until I changed the valve guide seals, so I figured it was worth replacing the [$16/set] seals now, when the cylinder heads were conveniently on the workbench, rather than try to do it when the engine is in the vehicle.

Removing the engine components

The next evening after work, I began removing the external engine compoents. I started with the power steering pump, then removed the alternator and a/c compressor. Then, I removed the intake manifold and its various fuel injection hoses and wiring.

I did take some pictures during the removal process, but maybe I could have taken more. Luckily I will be installing the power steering pump, alternator, a/c compressor, intake manifold, fuel injection components, etc., that are on the Subaru engine that is currently in the Vanagon. [This is because there are some differences between what's on Japanese and US models]. I spent several hours marking the hoses, lines and wires that are on the engine in the Vanagon, so I think it should turn out fine.

Correct engine arrives!

When the correct engine arrived, I went to the shipping doc to pick it up. Using the forklift, they put the engine and pallet into the back of my truck. I removed the shrink wrap that surrounded it, then sprayed some degreaser on the engine.

On the way home, I stopped at the car wash, and used the high pressure hose to blast away what little road grime was on the engine. [I'd rather have gotten it with some road grime on it, because it lets you see whether or not it was leaking anywhere.]

Engine arrives, but it's not the right one!!

The engine arrived, strapped to a shipping pallet. Tt looked great, but soon I noticed that it was a 2.0 engine, which is not common in the US [except for the turbo version, which this one was not], instead of the 2.2 engine I ordered

Initially the seller wanted to refund me part of the money if I would keep the 2.0. However I know that modern engines have so many computer controls that may or may not function in other configurations. Therefore I stuck to my guns and insisted that I get the engine I ordered.

The seller had to eat the cost of shipping the 2.0 back to the Midwest, then shipping the 2.2 engine to me. This obviously was not the happiest of solutions for him, but I did help him out by bringing the 2.0 engine to the shipper's loading doc, and going there again when the 2.2 arrived. That saved him having to pay the shippers come to my house for the pickup and drop off. Also, I sent him pictures of where the engines' identifying marks are located, so in the future he or his crew will not be confused by which models of these similar-looking engines they have.

This did eat up an extra week of time, but it was an honest mistake and the seller did his part to rectify it. Therefore I gave him a good ebay rating without any mention of the mixup.

Time to replace the engine??

When I bought the Vanagon, I knew its engine had serious problems and would need to be replaced. That's one of the reasons I got it so cheap. I thought it was a worthwhile risk...and it did get me all the way home! I've overhauled 7 or 8 engines before, so that part wasn't too overwhelming.

Considering that the Vanagon's oil pressure light came on a few times on the drive home, and that the engine was using so much oil, I thought that it might be better to find a replacement engine for it. [I could always disassemble the current engine at a later time and find out what was wrong with it.]

In Japan, the Goverment slaps very high taxes on vehicles once they have more than 65000 miles on them, so a large industry has been created by people who disassemble these Japanese Domestic Market (JDM) vehicles and ship the parts all over the world. Subaru engines are barely broken in at 65,000 miles, so I decided that this might be a good engine source.

After a few weeks, I found a JDM engine located in the Midwest on Ebay for a good price, and arranged to have it shipped to me.

Air conditioning?

The Vanagon's air conditioning system is an afterthought....an assembly bolted to the ceiling at the rear of the van. With the engine in the back and the radiator in the front, there is a lot of tubing, as well as a rear to front air duct that brings the cooled air forward. Not very efficient but better than nothing.

The seller was going to replace the existing clamshell [which holds the assembly to the ceiling] and had already bought another one in the junkyard.

I removd the old clamshell and discovered that the mounting bracket that supported the twin fans has cracked in several places. Some attempts had been made to fix them, but the bracket was in pretty sad shape. I repaired it using aluminum sheeting [from an old license plate], steel sheeting [from a joist hanger], sandwiched together with Liquid Nails and pop-rivets.

My father in law Salvador says I'm skilled at "mexicanadas" [simple yet effective jerryrigging], so I know he would laugh if he saw it. Using Liquid Nails again I glued the bracket to the clamshell so there won't be the vibration [when the fan was working] that I remember on the trip from Reno. Also I am replacing the clamshell's thin insulation with mylar-covered bubblewrap insulation. So. it will do a better job of distributing cool air.