How To Handle Reverse Coolant Manifold Temp Sensor

I checked and all the reverse coolant manifolds (Rocky Mtn Westy, SmallCar, Tom Shiels, etc.) have the temperature sensor in the same place, which leads to a problem connecting the Subaru intake wire harness back up to it. As you can see in the photo, mine is at least 6" short.  I figure there are 3 options to resolve this:

1. Get both a male & a female 3 pin connector, more wires, and make a pluggable extension.
2. Cut off the end, extend it with similar gauge wire to make it reach
3. Peel back the Subaru harness, stretch the wires for the sensor over and hope they reach.

I'm opting for #2, as recommended by RMW.
#1 seems about the same amount of work, but I'd have to source the connectors.  #3 seems like a lot of work for something that may not even fit after it is done, or maybe it will fit, but will be so tight, it will suck to work with.  So, #2 it is.

Installed New Subaru P/S Pump

Today, I bought a 2002 Subaru P/S pump from Super Rupair ($45) and installed it.  The original had been ruined when my engine tipped over onto it's front.  The install was easy.  My model of Subaru has a remote reservoir, so the RMW kit's power steering hoses are made to connect remotely to my VW Vanagon P/S reservoir.

The 2002 Subaru P/S pump sensor was not compatible with the 2001 intake manifold wiring harness.  Luckily, I had the old sensor and just connected that up to both the pump and wiring harness.  Glad I kept the old one around.

From $75 to Free

I ended up calling NAPA in Boulder. The nice lady, Sara, said they didn't have any spools of fuel/evap-rated hose. Then, she called me back an hour later and said she found a random foot of it in the store that she'd just give me for free. How's that for luck! From $75 at deal to free - can't beat that!

WTF... This costs $75!?

This hose needs to be replaced before I put the intake manifold back onto the block.  The old hose was brittle and cracked as they commonly are on these old Subarus.  If you are doing a Subaru/Vanagon conversion, REPLACE IT when it is easy to get at!  Anyway, I asked the Subaru dealership for a replacement hose, but they ONLY sell the whole kit-n-kaboodle, not just the bottom hose.  AND... they are charging $75 it.  Wow.  I'm on the look-out for a cheaper solution for sure.

Installed timing belt kit and water pump today

I'm very psyched to have done this work myself.  I messed up along the way, but I learned a ton and it will all be good in the end.  I used a Gates Timing Belt Kit and an Aisin Water Pump.  Both supply OEM parts and their quality is fantastic.  Remember to only use OEM parts on these critical areas of your engine and never buy them from a dealer, where they are way over priced.
Thanks to Tom and Paul for their insights and use of their tools to get the job done and to the members at http://www.ultimatesubaru.org/ forums for support as well.

Timing Belt and Water Pump installed!

Engine looking like new!!

Today, I wrapped up my efforts to clean the engine.  Overall, I've spent about 15 hours just dismantling and de-greasing the engine and this was a clean engine to begin with.  Anyway, tools I used were: citrus de-greaser in a water gun, spray bottle, foaming engine cleaner spray can, rags, tooth brushes, brass wire brush, and get this.. a set of chopsticks (advice from Paul).

Before

After

Other angles....

Ready for the Subaru/Vanagon FlyWheel!

Rough Day on the Subaru Engine Front...

Today was a tough one.  On Wednesday, the engine tipped over while I was cleaning it and today, after getting it up onto a proper engine stand, I found the power steering pump pulley was warped and the timing cover is cracked.  I'm hoping I can use some kind of epoxy or resin to patch it all up, but it will have to bond to this plastic and handle the heat of a motor pushing a fat old Vanagon around the mountains.

Crack goes horizontally across most of the cover

Crushed side and lost connector here.

The power steering pump on my engine is fine, but the pulley is hosed.  The problem with that is the pulleys suck to replace.  So, you are better off just getting a whole new pump.  Looks like this mistake is gonna cost me at least $70 (used P/S pump and epoxy/resin product) and unknown $$ of dollars and time to replace it that I hadn't figured on spending for this conversion.

UPDATE (January 20th, 2014):
Using epoxy worked fantastic.  I cleaned it off first, took off the gasket around it, then spread the epoxy throughout.  It is hard as a rock now and solid.  I even found the broken piece, so the whole timing belt cover is now in tact and functional.

Labeling the Subaru Wire Harness

Baxter stopped into the kitchen as I was deciphering and then labeling the critical wires in this rat's nest!  He called upon his demon powers to provide the much needed help labeling everything.  The two beers on the counter were just the start of the night!  :)

Labeling the Subaru Harness

Pulled Subaru Engine

Boulder Hybrids Garage

This week I worked with Paul Guzyk of Boulder Hybrids to pull the engine from my 2001 Subaru.  Along with the engine, we also got the wiring harness pulled and ready to send to Rocky Mountain Westy for the modifications to make it fit my van.

Then, I pulled the cruise control parts in hopes of using them to add cruise control to my van, which does not have cruise at all yet.

For more details on my cruise control effort, click here:
Subaru-Vanagon Cruise Control

Subaru Wire Harness pre-modification

Subaru engine successfully pulled!