Installing the VSS & OBD2 Connector

I ran the VSS and OBD2 signal under the van to the front so I could do a digital, speedo-based VSS and OBD2 connector up front as well as hook in the Subaru cruise control brains up there to it.

In this video, I recorded how I made the final VSS/OBD2 connector which connects to the ECU in the rear of the van.  This connector is for the cable that runs under the Vanagon to the dash.  I wired it to an weather proof connector so it is safe from the elements in the engine bay.  Then, to ensure the aluminum shielding properly dissipates the interference it collects under the van, I wrapped a wire with an eye-let on it and connected that to the van's engine bay where it is grounded.  Finally, (not shown), I sealed it up by wrapping it non-adhesive black vinyl tape and black wire loom.

Finishing Touches on the Wiring Harness

After testing the wiring harness last weekend, I felt safe putting on the finishing touches to it.  I loomed it and detailed the end result in my video here:

Finally! Starting the Vanagon with Subaru engine

The virgin start of my Subaru/Vanagon conversion went like this...

With fire extinguisher in-the-ready, Paul told me to give it a shot.  The first key turn was a dud.  Paul asked "did you do anything around the fuse box?"  Why yes... Yes I did!  I put in high-powered head light relays under there and ended up dislodging the main power cable from the battery.  Ooops!  With his electric sorcery, Paul troubleshooted the issue and we figured out where to re-connect everything.  To my defense, the Vanagon fuse panel blows.  Haha.  Literally.

On the second key turn, it fired right up.  As we celebrated, it puked gas all over the shop floor!  Evidently, I didn't tighten the fuel return hose very well :)  Thankfully, I turned it off before we needed the fire extinguisher.

But, as they say, third times a charm!

Check Engine Light Modification for Vanagon

I followed the instructions from my RMW manual to turn my outdated OXS light (e.g., lower left LED on instrument cluster) into a check engine light for my Subaru engine.  The engine bay is modified to connect the Subaru ENG LIGHT wire into your VW round connector's 7 pin.  That's pretty easy.  For the under-the-dash stuff, though here's the photos of the steps I did for those of you, who are visual learners.

First things, first... get your instrument panel off and accessible - not covered here!

The photo below shows the 14 pin connector that goes into the blue foil on the back of the instrument cluster.  Some are different colors depending on the year of your van, so either reference your Bentley or RMW manual, which has it listed.  The pins read right to left in this photo (1 on far right and 14 on left).  My 14 pin wire color was blue/green.

1986 VW Weekender 14 PIN for Instrument Cluster

If you are still confused about which pin is 1 vs. 14 when doing this mod, look at the connector.  You can see the numbers on it.  Pin 14 is on the top in this photo.

Numbering is on the connector, if you are confused.

Following the RMW instructions, I cut the 12 pin (yellow, high oil pressure light) wire and the 14 pin OXS wire (blue/green on my '86 Weekender). Note where I cut them, to make it easier to connect during the next step.  The yellow wire on pin 12 will be left hanging and the pin 14 blue/green wire that dropped back off the connector will be left hanging.

After cutting each wire

I connected the yellow wire coming from the engine bay to the blue/green wire going to pin 14 with a non-insulated butt-connector and "heat shrinked" it with clear heat shrink.  Then, I used liquid tape to cover the end of the unused pin 12 yellow wire and did the same on the unused end of the blue/green wire that dropped off when I cut it off of pin 14.

Yellow High Oil Pressure wire connected to OXS light

There you have it.  A visual demo of how to make the OXS on your instrument cluster into your CEL light for your Subaru.  Total time: 30 minutes.

Transmission-Main Seal "Cover" Won't Fit!

This was another, albeit minor, BUMP in the road on my Subaru/Vanagon conversion (~1 hour of my time to modify it).  The part is not a show stopper to the conversion, but it is reasonably important.  It is used to cover the gap between the Vanagon transmission and the Subaru engine (under the main seal) - keeping the main seal area nice and clean.  It did not fit properly because the oil pan was in the way.  I have a stock Subaru oil pan and I would have thought the manufacturer would make a cover that fit OEM parts at least.  RMW currently distributes the cover in their kit even though it is from a third party manufacturer.  They should just start making it themselves, because if they did, I know the quality would be better and it would fit! :)

To do this little project I needed a grinder.  Had I been in my own garage, I would've been screwed and this simple thing would've been an expensive endeavor.  But, as luck would have it, Paul's shop has one!  

Mark the area to grind out

After grinding it down, it looks like this.

Sealant for good measure before installing it