EJ25 in 1972 Beetle

[jamesdkline]

Hi all,
I'm doing a full restoration of a 1972 Standard Beetle with a SOHC EJ25- I'm finally to the point of working on the engine conversion so it's about time for me to start a thread here. I've read just about every post on every thread here - I wouldn't have the courage to attempt this without all of you spending so much time posting and helping each other. So thanks!

My restoration thread is on thesamba here http://www.thesamba.com/vw/forum/viewto ... highlight=

I'm installing an EJ25 out of a 2001 Impreza RS. I'll be using a Stinger ECU from Outfront.

Here's the engine on a wooden stand that I threw together to help me move it around. I can slip a jack underneath the stand and shuffle it around the garage by myself.


I bolted on the Kennedy adapter plate, flywheel and clutch. (clutch and flywheel photo is missing!)


Here's the first trial fit into the engine bay. In short - it doesn't fit. I feel like I'm trying to shove 10lb of crap in the 5 lb box.

This picture is deceptive. It looks like it fits but that's because I have the car jacked way up in the air.
Hopefully today I'll get some time to start trimming the engine compartment to squeeze this thing in.

[Buggin_74]

You'll need to trim the bumper mounts slightly to clear the timing belt covers
Some creative panel beating with a hammer may clear it enough.

That's the problem with the phase 2 SOHC heads, just a fraction too wide.

[jamesdkline]

I'm making some slow progress.

I got the engine bay trimmed enough to get the engine temporarily in.


The I pulled the engine back out and replaced the spark plug tube seals.


I cut out the spare tire well...


...to fit this. It's an ebay special, supposed to fit a 1st gen RX-7.


I have one question though about the breather routing, if anyone can help.

This is the left side valve cover breather.


When I bought the engine it was just hanging loose


Should it be connected to the intake runner here?


On the other side of the motor the valve cover breather is attached to the intake but the fitting on the other intake runner isn't the same... can anyone shed some light on the proper valve cover breather setup? Should it tie into the crankcase breather/pvc??

[Buggin_74]

That other side isn't hooked up correctly either in that last picture.
The port it's connected to is actually for the brake booster.

All those breather hoses from the crank case and rocker covers connect to big plastic donkey dick hose with joins the air box to the throttle body.

The small vac port is for fuel pressure regulator (well on early engines anyway),
THat is the hose for it directly below, is it connected to another port or just hanging there?

if it is connected that one above it would be for cruise control or MAP sensor.

[jamesdkline]

That other side isn't hooked up correctly either in that last picture.
The port it's connected to is actually for the brake booster.

All those breather hoses from the crank case and rocker covers connect to big plastic donkey dick hose with joins the air box to the throttle body.

The small vac port is for fuel pressure regulator (well on early engines anyway),
THat is the hose for it directly below, is it connected to another port or just hanging there?

if it is connected that one above it would be for cruise control or MAP sensor.

Thanks Joel! I spend some more time looking at the pictures in your thread (which is awesome, by the way!) and on some subby message boards and I understand now. I don't have the 'donkey dick' so I couldn't see what fittings were on it to begin with.

[Buggin_74]

Actually I was just thinking, yours being an 00s model would have had the air box that mounts straight to the throttle body without the donkey dick hose between them.

So like this one, you can see the rocker cover hoses where they connect on the side just behind the fuel lines:

[jamesdkline]

I had yesterday and today off work and the kids are still in school so I made some progress on the cooling and fuel systems.

I made a bracket to mount the fans onto the radiator.


And then spent the better part of today trimming the car and trying to figure out how to mount the stupid thing. Here's what I came up with - not perfect but I think it'll do for a first revision.




I also made a small scoop under the radiator to try and direct more air up through it. I'll trim away a little more of the body later to make the hole bigger so more air can get in.


One last thing I came up with is a fuel surge tank - made from iron pipe. I saw the idea on another forum and thought I'd try it. The ebay surge tank i bought ended up interfering with the tie rods so I can't use it. I need something smaller than whatever I can find commercially.

If it doesn't work as a surge tank i think it'll make a nice pipe bomb.

[883]

If it doesn't work as a surge tank i think it'll make a nice pipe bomb.

Let us know how it goes with the NSA guys.



Project's lookin good.

[Steezin]

i like the surge tank, how did it work out?

[jamesdkline]

I've been hard at work but have surprisingly little to show for it.

Instead of getting the vent window trim rechromed I bought a used oven and powder coated them myself. It was way cheaper and I'm pretty happy with the result. I've since powder coated a bunch of other stuff too.


I installed a full set of VDO Series 1 gauges in the dash.


Here's the Summit heater mounted under the rear seat, opposite the battery. I should be able to route the air output into the heater channels like stock.


Because the heater is under the seat I had no choice but to mount the computer in the package tray.


I've also started rewiring everything under the dash. It's not exactly my favorite part...


Finally here's my fuel surge tank/fuel pump setup.

[Steezin]

looking sexy!.....and then...

[panel]

Part # for the Summit heater? Cost ?

[jamesdkline]

Part # for the Summit heater? Cost ?

It was around $140. There are 4 sizes to choose from.
http://www.summitracing.com/search/depa ... mit-racing

[Steezin]

Hey man, I am sure you already solved this problem but I figured I'd post some pictures up anyways... This is in reference to the breather tubes on your heads.

The first picture just shows you the hose (sorry I had already taken the picture, didn't want to waste it)

photo 1 (1).JPG

The second picture shows where it has been T'd with the hose that connect to the other side.

photo 2 (1).JPG

The third picture shows where the top of the T heads to the intake (it is the one in the back).

photo 3 (1).JPG

(I believe this is how they are setup from outfront)

[Steezin]

On the third picture it is the one to the far left (all the pics rotated on me)