Subaru Vanagon Conversion: The Ultimate Upgrade

The California Legal Subaru Conversion: Revitalise Your Vanagon

For many Vanagon owners, the allure of these iconic vehicles is undeniable. Their spacious interiors, versatile nature, and classic styling make them perfect for adventures. However, the original Volkswagen engines, while charming, often fall short in terms of power, reliability, and maintenance ease. This is where the Subaru Vanagon conversion shines, offering a modern, powerful, and remarkably reliable solution that revitalises your beloved VW van.

The Subaru conversion isn't just an engine swap; it's an enhancement that brings your Vanagon into the 21st century. It leverages the renowned engineering of Subaru to provide a driving experience that is leagues ahead of the stock setup. Let's delve into why this conversion is the clear choice for many and what it entails.

More Reliability, More Power, More Savings

The advantages of a Subaru engine conversion for your Vanagon are substantial:

• Japanese Engineering & Reliability: Rely on the proven track record of Japanese engineering. Subaru engines are known for their durability and longevity. Finding parts and qualified mechanics is also significantly easier compared to sourcing components for older VW engines.
• Increased Power: Experience a dramatic boost in performance. The Subaru engine typically offers around 130 horsepower and 135 ft/lbs of torque, a significant increase from the Vanagon's original 89 to 94 horsepower and 117 ft/lbs. This translates to approximately a 50% increase in power!
• Enhanced Fuel Economy & Savings: Enjoy better fuel efficiency and the ability to run on cheaper 87 octane gasoline. Furthermore, reduced maintenance needs contribute to significant long-term savings.

Creating Your Dream Vanagon

When it comes to replacing Vanagon engines, the Subaru conversion stands out. It offers a more compact engine that fits neatly into the Vanagon's engine bay, often without altering the engine lid or bed, and crucially, without sacrificing ground clearance on 2WD models (a minor 1" reduction may occur on 4WD with a modified skid plate).

The power upgrade is substantial, but it's the overall package that truly impresses. Unlike some conversions that can look like a "Frankenstein" creation, the Subaru conversion is designed to integrate seamlessly, maintaining the aesthetic integrity of your Vanagon.

Cost-Effectiveness and Maintenance Simplicity

The financial benefits extend beyond just fuel savings. Consider the reduced maintenance costs:

• Tune-Ups: A Subaru engine tune-up primarily involves replacing spark plugs and spark plug wires, with the computer handling the rest. This is a far cry from the manual timing and mixture adjustments required for the original VW engine.
• Diagnostics: Subaru engines feature on-board diagnostics (OBD1) through their fuel injection system. If there's an issue, the computer will display a code, simplifying diagnosis and often negating the need for expensive diagnostic scans.
• Serviceability: Any mechanic familiar with Japanese cars can readily diagnose and repair a Subaru engine, making maintenance and repairs accessible wherever you are.
• Eliminating Common VW Issues: This conversion effectively bypasses the costly cylinder head reseal that many stock VW engines require every 80,000-100,000 miles, a repair that can cost around £2,900.

A More Robust and Simplified System

The Subaru conversion also simplifies the Vanagon's often complex cooling system. The numerous small and large cooling hoses are replaced by just two metal pipes and three robust, easily accessible hoses. Fewer hoses mean fewer potential points of failure.

Furthermore, you receive a completely re-done and bench-tested wiring harness, ensuring perfect electrical integrity, unlike the often-aged original harness. The conversion typically includes a new stainless steel exhaust system with a catalytic converter and a new clutch, providing a comprehensive overhaul.

Engine Longevity and Design

Subaru engines are engineered for impressive longevity, often exceeding 300,000 miles. This is attributed to intelligent design features such as:

• Factory-designed counterbalanced crankshaft
• Four valves per cylinder (compared to the VW engine's two)
• An overhead cam on each cylinder head
• An advanced fuel injection system

These factors combine to make the Subaru conversion the smoothest, most balanced, and lowest maintenance option for your Vanagon.

The Cost of the Vanagon Subaru Conversion

For a California-legal 2.2-litre Subaru conversion, prices typically start at approximately £22,000. This investment brings a significant upgrade in performance, reliability, and long-term cost savings.

Which Vehicles Benefit from the Conversion?

Currently, this conversion is most commonly performed on water-cooled Vanagons, specifically the 1983.5-1992 gasoline models and the 1982 diesel models.

The Conversion Process

The process involves:

1. Sourcing and professionally rebuilding a Subaru engine using high-quality factory parts.
2. Installing new outer seals, pulleys, belts, a shortened oil pan, clutch (for manual transmissions), cooling system components, hoses, and exhaust.
3. Removing the old VW engine and wiring harness.
4. Installing the custom conversion wiring harness and connecting the new Subaru engine.
5. Comprehensive testing for codes, leaks, emissions, and optimal running conditions.
6. Multiple extended test drives to ensure everything is functioning perfectly before returning the Vanagon to its owner.

To date, numerous successful Subaru VW conversions have been completed, demonstrating the expertise and dedication involved.

Do You Sell VW Subaru Conversion Kits?

Currently, complete conversion kits for home installation are not offered. The conversions are performed in-house by experienced specialists.

Maintenance After Your Vanagon Subaru Conversion

To ensure the longevity and optimal performance of your new Subaru engine, follow these maintenance guidelines:

• Oil Type: Use 5W-30 non-synthetic oil.
• Coolant: Subaru Long-Life coolant is recommended. Prestone or an equivalent can be used if Subaru coolant is unavailable.
• Tune-Ups: Schedule tune-ups every 30,000 miles.
• Oil Changes: Perform oil changes every 3,000 miles.

Breaking In Your New Subaru Engine

Proper engine break-in is crucial:

• For the first 1,000 miles, drive gently. Avoid hard acceleration and braking.
• Do not exceed 3,500 RPM. Vary your engine speed by mixing city and highway driving.
• Limit the use of cruise control.
• After 1,000 miles, return for an included oil change and inspection.

The 2.5L Subaru Engine Conversion

For those seeking even more power, particularly for heavier rigs or high-elevation driving, the 2.5-litre Subaru engine conversion is an excellent option. Sourced from popular models like the Subaru Outback and Forester, this engine offers:

• Power Output: Typically produces 165-175hp and around 170 ft-lbs of torque.
• Engine Type: A single overhead cam, horizontally opposed 4-cylinder engine.
• Performance Characteristics: Delivers strong power across its RPM range, making it ideal for towing and high-speed cruising.
• Reliability: These engines are known for their reliability, especially when professionally rebuilt with high-quality parts and a good warranty.
• Serviceability: Parts are readily available and cost-effective in North America, and service is straightforward.

This conversion transforms your Vanagon, making hills and higher altitudes feel effortless. It's a popular choice for road trippers and those who demand more from their vehicle.

Frequently Asked Questions

Q: How much does a Subaru Vanagon conversion cost?
A: California-legal 2.2-litre conversions typically start at around £22,000. Pricing for 2WD automatic models may vary.

Q: Which Vanagon models can be converted?
A: Currently, water-cooled Vanagons from 1983.5-1992 (gasoline) and 1982 (diesel) are the primary models for this conversion.

Q: Is the Subaru conversion legal in California?
A: Yes, the conversion is 100% California legal and legal in all other states.

Q: Is the conversion noticeable aesthetically?
A: The conversion is designed to be clean and integrated, not appearing as a "Frankenstein" modification.

Q: Can any mechanic work on a converted Vanagon?
A: Yes, mechanics familiar with Subaru engines can easily service and repair the converted vehicle.

Q: What are the maintenance requirements for a converted Vanagon?
A: Regular oil changes (every 3,000 miles), tune-ups (every 30,000 miles), and using the correct oil and coolant are key.

Q: How long does the conversion process take?
A: The timeline typically ranges from 4 to 8 weeks.

Q: Which Subaru engine is used for the conversion?
A: Common conversions utilise the 2.2-litre or the more powerful 2.5-litre horizontally opposed Subaru engines.

In conclusion, a Subaru Vanagon conversion offers a compelling blend of modern performance, enhanced reliability, and cost-effectiveness. It's an investment that breathes new life into your Vanagon, ensuring countless more miles of enjoyable adventures.

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