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Author: Subject:  Picked up a Caravelle
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posted on November 7th, 2011 at 12:50 PM



Getting the aircleaner sorted, got it all rubber mounted. Using a VS Commodore housing which has the same A360 element that the Subaru uses. This is just the mockup so I will be getting a better housing from the wreckers and filling in the holes. Wedge seems to be working well but still need to trim the bulkhead a little and clean up the cut from the original install(lots of sharp edges).

Wedge changes the length of the accelerator cable and also the cruise control cable.

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posted on November 7th, 2011 at 06:31 PM



Lookin good.....:cool:



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posted on November 7th, 2011 at 08:21 PM



The old power steering pump had been run to destruction and had left steel and aluminum filings all throught the system. Flushed out as much as I could then installed a Z9 on the return line to pick up the filings before they got to the new pump.

Going to fit a Magnefine magnetic filter later.

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posted on November 13th, 2011 at 06:08 PM



Moved the cable brackets back and up a little, now the cruise control actuator hooks up properly. Welds are a bit ugly but it won't fall off.

Fitted up the exhaust and decided that I not a fan of the original donut hemispherical gasket thingys. You can also see the reinforcing plate for the engine carrier bar which ties in with the bolts for the bumper/towbar.

Extended the stud on the subaru starter, with the starter, stereo power and alternator cable terminating there it was just too short.

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posted on November 14th, 2011 at 04:47 PM



Better view of the extended stud.

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posted on November 16th, 2011 at 05:05 PM



Pulled new heater lines through (8m of it), quite a dirty job. Plastic welded the air cleaner housing and fitted the AFM. Used the bellmouth from the VS housing.

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posted on November 21st, 2011 at 05:14 PM



Stripped the wiring loom back over the weekend, was not too bad of a job. Didn't start the first time but then it does help if you remember to plug the ECU back in.:rolleyes:

But it RUNS now. :cool:

Still have to rewrap it and move a few thing but the loom it is close to done.

Dash temp gauge and oil pressure light are working and the ECU is controling the radiator fan.

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posted on December 6th, 2011 at 03:51 PM



ECU is mounted up properly, the wiring is a lot more organised than it looks, the engine bay side is finished . Had to work out what I thought was a cold start issue but turned out to be an automatic inhibitor problem preventing startup until the starter was off.

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posted on December 6th, 2011 at 04:38 PM



Been working on the accellerator cable and found if I set the idle up properly there was no full throttle, if I set up full throttle there was no idle. Also the smallcar throttle cable has no way of adjustment apart from at the pedal under the van (if you have done this you will know this is a pain to get to). So I removed the VW fitting from the smallcar cable and replaced it with the subaru adjuster. This meant I had to change the cable bracket back to original style. To get full throttle movement I extended the arm at the pedal to get more travel.

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posted on December 6th, 2011 at 09:13 PM



Awesome work. Its amazing all the fiddly bits that need doing in these conversions.

looks like you are almost there.

Cheers,

Scott




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posted on December 6th, 2011 at 09:27 PM



Thanks, some of the small stuff can be quite time consuming.



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posted on December 6th, 2011 at 09:55 PM



nice score n great work :tu:



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posted on December 9th, 2011 at 06:53 PM



The front end is all in bits and pieces to do the ball joints and other things. Did some reading up on press the lower ball joints in and worked out it was one "those" jobs without VW tool X,Y and Z.
So it was tool making time again. It all looks a bit bulky but I don't have access to a good choice of steel so I used what I had.

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posted on December 9th, 2011 at 06:56 PM



More

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posted on February 10th, 2012 at 06:36 PM



I've changed to a Telstra Syncro bumper/towbar, the old bumper was good but the towbar fouled on the new engine mount reinforcing plates. Converted it to a hitch receiver before if fitted it up.

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posted on February 10th, 2012 at 07:26 PM



And just to annoy the purists I installed a set of these.

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posted on February 10th, 2012 at 08:17 PM



Where did you get the mud spats from?
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posted on February 10th, 2012 at 08:34 PM



Where else, off a Syncro.

This one http://forums.aussieveedubbers.com/viewtopic.php?tid=86430&page=1#pid807375 




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posted on February 10th, 2012 at 08:43 PM



Yeah,I am after some,have damaged mine.
Can buy 3 out of 4 brand new(dont make nsf).
Trying to find some locally.
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posted on February 12th, 2012 at 07:38 PM



Been trying to sort out the shifter, the shifter guides were quite worn, rubber bellows and end cap gone. The plastic guides are still there and good enough for later replacement. Put the shifter guides in the lathe and took 10mm off the top of both. Then made some 10mm spacers to go underneath. This makes them a bit wider on the top but the shifter still seem to be shifting ok and I can always take them down on a linisher later if necessary.

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posted on November 24th, 2012 at 09:18 PM



Well finally it is registered and on the road. Had some teething troubles.

1 Stalling occasionally coming up to traffic lights on deceleration, yes I thought it was a VSS issue at first but the idle air control valve just needed a good clean.

2 Starter stopped engaging properly so replaced it with my spare. Found I had lost the ball bearing which sits at the end of the solenoid plunger when I serviced it. Doh!

3 Power steering pump came loose, a little less haste in getting it going would be better. Doh! again.

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posted on November 24th, 2012 at 10:12 PM



Love the performance of the EJ22, took it up the range to Eungalla and back today, about 180 km round trip. Performed well going up the range and cruises great on the highway.


Here are a few more details on the conversion.

Salvaged the relay box from the engine bay and used it for the radiator fan relays.

Used a cruise control sensor from a jetta (hall sensor) for the VSS.

Reinforcing plate for the engine mount/towbar.

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posted on November 24th, 2012 at 10:39 PM



Also found these along the way.

Bent gearshift lever, had everything adjusted up nice and couldn't work out why I was still nearly hitting my knuckles on the dash changing gears.

Rear wipers were not parking properly and tracked it down to this burnt out connector. Ended up having to replace the fuse box and splicing on a new connector from a space loom.

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posted on December 1st, 2012 at 06:57 AM



Gear levers are available new from VW for less than $100. Just make sure that you get a RHD one.



I read it on samba, so it must be correct.

Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!:lol:
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posted on February 6th, 2013 at 08:30 PM



Small update. Put about 5000 Km on it so far and has been going well. Managed to get the air-con up and running but the compressor is leaking oil so more work needed there. Developed an oil leak on a trip up to Townsville, wasn't a big leak but sprayed all over the tailgate on the highway. Was a little hard to track down as it was so slow, striped off the oil pump and resealed it also replaced the crank seal. No luck there, turned out to be the gudgeon pin access plug in the front of the block. Love this motor, since the fix it hasn't leaked a drop of oil.

Big news is now it is up for sale. Had no intention of selling when I started this but something came up that changed my mind.

All I can say is...

http://images.thesamba.com/vw/gallery/pix/791454.jpg


So I'm back at square one conversion wise.




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posted on February 7th, 2013 at 07:27 AM



Puch me!!!:lol:



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