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HomeVanagon 2.2 & 2.5L Conversions
Vanagon 2.2 & 2.5L Conversions
A VW Vanagon with a Subaru engine, the perfect match!
The Vanagon is perhaps the most versatile of vehicles. It can be everything from a moving Van to a motor home and to some even a sports car. VW upgraded the engine several times after starting with the 2.0L 70hp air cooled engine the first 1980 model, eventually ending up with 2.1L and 95 horsepower in the 1986-1991's. From the beginning, the water cooled four was plagued with head gasket problems and VW dealers had their hands full with warranty repairs. They never seemed to be able to cure the corrosion issues on the Wasserboxer's heads and many long term Vanagon owners necessarily look upon this $2000-$3000 repair as a regular maintenance item.
After 27 years in the VW business and with a love of the Vanagon's unique qualities, we wanted to find an engine that was as good as the rest of the vehicle. Consider the Subaru engine, a water cooled flat four with 135-173 horsepower. Installed in a Vanagon, these engines provide a very welcome power increase over the VW engine and after a few miles of driving a converted Vanagon, you begin to wonder why VW didn't update their engine design. Soon you realize that urging your steed onwards by hunching over the steering wheel as you draft up close to an 18 wheeler trying to maintain 60mph is a very stressful position that is not necessary when you have 50 more horsepower. As you ease off the throttle at 70, you lean back in your seat and watch the scenery and the other Vanagons go by. Many conversion owners say they can drive a great deal further and arrive at their destinations more relaxed. Could a Vanagon with more horsepower actually be safer? It certainly seems possible.
About the engines
These Subaru engines are very impressive. They are state of the art with 5 main bearings, 4 valves per cylinder and two overhead cams. They feature an engine management computer capable of learning as you drive with input from crank and cam position sensors, knock sensors, oxygen sensors and it controls the spark, fuel injectors, and timing. It has no distributor, cap, or rotor. The outstanding reliability of these engines is evident by their popularity in light aircraft.
The 2.5L Subaru engine makes 165-175hp and is perhaps the perfect Vanagon engine. It has great torque throughout the rpm range and keeps up with traffic easily, even in the heavier Westfalia and Syncro and runs extremely well behind both the manual and the automatic transmissions. Fuel mileage has proven to be better than with the stock engine, even with the additional power.
As a horizontally opposed four, the Subaru motor fits like it was meant to be there and all the original Vanagon options can remain functional; cruise control, air conditioning as well as the Syncro skid plate. All of our conversions include an extensive list of parts that we have developed to make the conversion fit and function better than the original engine.
See our completed Vanagons page for more photos.
The Cost
The cost to install a Subaru four cylinder non-turbo in a Vanagon 2wd is $6475 plus the cost of the motor, which is generally between $1000 and $4000.
Engines available as of August 2010
Please note that while our in-stock engines can vary from day to day, we can generally supply an engine that meets your needs within one to three weeks.
2006 Impreza 2.5L with 41,075 miles - $3975
OBD1 emissions special: High torque 2.5L engine with brand new shortblock and OBD1 emissions - $4975.00
2.5L Engine Cost Estimate
Mileage - Cost including maintenance parts
5,000 $5500 and up, may take a while to find.
10,000 $4,750-$5,500 may take some time.
20,000 $4,500-$4,750
30,000 $3,875
40,000 $3,425
50,000 $3,150
60,000 $2,875
70,000 $2,675
80,000 $2,475
90,000 $2,250
100,000 $2,000Installation Price includes
- Stainless steel header
- SmallCar aluminum oil pan for stock ground clearance with stock oil capacity
- Engine mount with stainless muffler support and clamps
- SmallCar designed bellhousing for manual Vanagons and Syncro- adaptor kit for automatics
- Dipstick located behind license plate door
- New engine matched clutch, pressure plate and release bearing for manual Vans
- For automatics, external transmission cooler included
- New radiator
- Modified ECU harness with the engine control computer mounted under the rear seat
- Power steering (when equipped)
- All engine cooling system parts and modifications
- New rubber engine mounts
- Intake and air filter system
- All fluids
Optional Items
- Complete stainless exhaust system - $649
- Air Conditioned cars - $485
Note: This cost is based on a Van with properly functioning A/C.- Cruise control (if already equipped and operating) - $150
- Syncro skid plate modification - $125
- ScanGauge driving computer installed $195.00
- 7,000 RPM tachometer face w/recalibration $150
- White gauge face set with 7,000 rpm tachometer - $225
- Wheel and tire upgrades
- 11" vented front brakes
- 10.4" rear disc brakes
- OME, HD shocks
- HD springs
- Transmission repairs or 4th gear changes
- Limited slip differential for manuals, automatics & Syncros
- Propane heaters for camping
Payment terms
Before arrival of your Vanagon we generally get a deposit of approximately the engine cost to acquire and prepare the Subaru engine.
Upon delivery of your Vanagon for the installation work, a 50% deposit is required with the balance due upon completion of the work.
There is a $15.00 per day storage fee after 5 days.
Let us build your dream Syncro !
Do you have a desire for a Syncro Multivan? Or how about a Syncro Carat? Maybe you just happen to own a 1985 Camper with 21K on the odometer and you want better traction in all weathers. We can build it for you and at the same time install a Subaru engine to give you the ultimate in power, traction, economy and reliability! Please contact us by email or phone to get more details about this conversion.
About your carbon footprint
Research has concluded that it takes the equivalent of more than a year's worth of fuel to build a new vehicle. Scientists determined this by doing a lifecycle analysis; a detailed study of the raw materials used to build the vehicle, where the materials came from and the energy it took to collect them. Carbon used in manufacturing is important, since manufacturing is 10-15% of the car's lifecycle carbon footprint. This is referred to as the vehicle's embedded energy. If the car you have is reasonably efficient, then getting rid of it and buying a new eco-friendly car may actually negate a lot of the benefit of having a car that gets better mileage and is cleaner.
A Vanagon conversion may be the perfect answer; reuse an older Vanagon, install a recycled Subaru engine and have a vehicle that gets better mileage and has low emissions.
Customer comments
The van is running great. I put it into 4th leaving Tacoma, and never geared down until the border. There is a hill on the main road of our island that the other Syncro Westy on island with a Go-Westy 2.5 can almost make in 4th. This van sails up the hill in 4th gear. I'm very pleased and barring the unforeseen I'll be back next fall or winter for the brake up-grade and the drive shaft with the de-coupler. I'll do my best to send more vans your way.
Don
After 100000 miles
"I wanted to give you a progress report on my Vanagon to Subaru conversion that you did just before Christmas 2001.""First, as you know I have always kept close track of my '87 Vanagon's gas mileage. For the entire six months before your conversion I averaged 17.5 miles to the gallon with the 2.1 VW engine. I now have 100,000 miles on the 2.5 Subaru engine you put in and I am happy to report I am averaging over 20 miles to the gallon! And that is with 50-50 city/highway driving. I am sure I will do even better this summer when I take my cross country trip."
"The engine is running beautifully, and it is so quiet at idle that I sometimes have to look at the tach to make sure it is still running when I am at a stop light. The extra power is the added bonus that is hard to believe. I remember that I use to have to downshift to get up most of the hills in my neighborhood. Even in cruise control on the highway the engine would lug and I would have to downshift up the steeper grades. Now if I set it at 65 it stays there with no sign of slowing down."
"I guess the greatest statement I can make is that I have grown so accustomed to my new Vanaroo that I hardly notice that the change was done. Except for less noise, improved gas mileage, and the acceleration, one wouldn't notice at all."
"Thank you for being so helpful with the conversion. You were always there to answer questions and to make things right if I had any concerns. I will gladly answer any questions anyone might have about
the conversion you did for me. I really think your onto something big, and I am proud to be the first 2.5L Vanaroo in Western Washington."
Dave
EmissionsThe Subaru engine runs very clean. Whereas the stock engine idles somewhat rough and therefore has a tendency to high hydrocarbons, the Subaru idles very smoothly and runs very clean.
Please call us about our new "High Torque" Subaru OBD1 engine, with 160 hp and 155 lb/ft of torque. These come with a brand new shortblock.
Warranty
All new parts have a 6 months or 6,000 mile warranty. Used parts have a 30 day warranty. Extended warranties are available on request. If the vehicle cannot be returned to us for warranty service, repairs at another location should be authorized with us before the repairs are completed. Diagnosis is only covered if it is performed in our shop.
What about my old engine?
There are a few parts from your old engine that are needed for the conversion: Rear crossbar, and muffler and cat if new ones are not desired. All other old parts should be picked up with your Van if you wish to keep them.
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