33) Pieces parts

I've been ordering parts left and right for the engine. I'm replacing as many seals and gaskets that I can find on the engine. I'm leaving the head gasket for now, because I'm not sure the condition of it, and I'm planning on tearing this thing down next winter anyways. I just want to get it back up and running leak free to see how she handles. You can also see the new oil pan there. The original was rotted straight through! Wow, I know!



Hose clamps and various tubing that I found on McMaster Carr. The blue tubing will be used for the heater core which will be placed under the back seat.



Some gas delivery items from Summit. There's an external fuel pump, aluminum 5/16" tubing and some NPT barbed fittings that will screw into bungs that I'm going to weld into my gas tank.



This was a great tip that I found on one of the many Subaru -> VW websites. It's a lower water manifold for a 2.5 RS. It is pointed in a better direction then the OE Legacy one. This way the lower coolant hose will be pointed straight towards the front of the car.

32) Intake and coolant manifold mock up

After cleaning the engine, I started messing around with intake positions. Putting the intake on the stock way makes the throttle body point directly at the firewall. I don't want to cut the firewall, so I needed to find a better way. Thankfully the Internet has many Subaru -> Beetle projects, and I found that you can flip the intake 180 degrees! Works great, except I see that the stock intake piping is too big and will hit the decklid. My plan here will be to get some 90 degree pipe bends, and a 90 degree silicon elbow to connect to the throttle body. (More pictures to come)



Here is the other side. You can also see the coolant manifold has also been flipped around 180 degrees. This will make for nicer piping location to the front of the car. I didn't want to have to pipe from the rear of the engine and down past the exhaust. My plan is to use aluminum tubing and radiator hose to go from below the right axle, inside to the center channel and out the front of the car from the middle of the beam. Stay tuned for pictures of the whole thing!

31) Clean up on isle EJ

Corny I know, but anyways... A few shots of current progress. I used some foamy engine bright, and some brushes to clean as much of the dirt and crud away. For future reference, get an engine that is A) Almost new, or B) Not from the North East. This thing was dirty!



Valve covers after a good clean and a little work with a 3M scuff pad.



New water pump! I will be replacing as much as I can without taking apart the long block (for now). I just want to get everything in the car and mocked up enough to start it, and possibly drive it for a bit to work out the bugs. If the rings are worn, or head gaskets need attention, I will have a fun project for next winter!

30) How it got there

I wanted to show the adapter plate, and how this Subaru engine bolts to the Beetle. This show is of the KEP adapter plate bolted to the engine. The studs are installed to slide right into the VW transmission. All the hardware came with the kit: Adapter, flywheel, nuts & bolts.



This is with the KEP flywheel bolted into place. This allows the VW clutch, and the VW starter to mate right up! (Notice the little flywheel lock on the upper right. Makes life a little easier when torquing down the bolts)



I elected to buy a stage 1 clutch / pressure pate from KEP. Here is the clutch matted up to the flywheel. The kit even came with the alignment tool that you can see in the center.



And finally here is the pressure plate bolted up and torqued down. Be sure to tighten slowly and in a star patter here, as you can bend the pressure plate if done incorrectly.



I also wanted to show a picture of the VW transmission all ready for the engine. I got a new bushing and throw out arm. The clutch kit also came with a new throw out bearing you can see here.

29) It fits!

Here is the Subaru EJ22 all bolted up and the body temporarily back down on the chassis. This thing fits in there without any modifications to the body. (Note: I will need to modify the rear apron a bit for it to fit around the timing belt cover) I bolted the engine in with a Kennedy (KEP) adapter plate.

I can see now that there are a couple of items to address here. First of all the throttle body is pointed right at the firewall. I will rotate the entire intake assembly around 180 degrees. Secondly the coolant manifold is pointed strait towards the back of the car. I will flip that around 180 degrees. This will have to be cut and re-welded to clear the crank case (Pictures to come).