Turbo EJ22 in my BUG! Install Part 01

[Music] in this episode of velocity labs were pulling the ej20 2t out of this Subaru and we're putting it in that bug actually we're not putting it in the bug in this episode in this episode we're just pulling the motor out of the Subaru and then it's gonna sit on an engine stand in the corner of my garage probably for like a year yeah so it's been a little more than a year but we are finally getting moving on project pugford I didn't say finish I said moving slowly alright so the way that this project started was I originally sold the motor out of the bug to help pay for the 97 talon that I picked up from New Mexico so it's finally time to take that ej 22 t that I had pulled out of my legacy a couple years ago and get it installed thing is I've always had the plan of running a reverse gear Subaru 5-speed transmission in this but I don't have the money for that so we're gonna go ahead and go with the cheaper option which is a killer adapter plate from ke P so let's get to work alright so we've got the bug here doing engine and obviously this container right here is the ECU and wiring harness and a couple other random bits we got the EJ 22 over here and the thing that's gonna let us get it in there is right here $500 chunk aluminum in the box we have this shiny new flywheel and then underneath that is the adapter plate itself which allows us to bolt the ej20 to T right to the stock Volkswagen transmission rest in peace clutch [Music] all right first thing we're gonna do is pop the fenders up so we can pop the rear apron off that will give us plenty of room to work in there so I pull this up and first thing that I found is a big wasp nest anyway let's get these fenders off [Music] [Music] oh yes I would say now the only thing left to do let's get that ej20 to up on the crane shove it in there to see how she fits actually no that's not what we need to do next all this sound deadening stuff has to go and I also have to clear out the inside back package tray because we're gonna need access and iron I'm going to be cutting a hole right about there ish for the turbo to sit through but yeah all that sound deadening stuff has to go a couple those wires that don't know where I have to go but yeah we're getting close the spec firewall actually looks really good somebody must have like Ryan aligned it or something like that you can see I scraped off a little bit of it right there the original color of this was white so yeah that must have been rhyolite it looks great I'll Ben I'd be cutting a big hole right about here ish because that's where the turbo and the downpipe are gonna go next up we need to get rid of all of the stuff that we no longer need in the engine bay likes wires heater hoses etc here's a pile of rear insulation that is now garbage next up we got to pull the rear seats of trim so we can cut some holes in the back and there we go looking good we still need to tear up some carpet [Music] now we're ready to move the engine out of the corner where it's been sitting for about a year and a half and get it mounted [Music] there we go one dangly engine and the biggest thing in the way right now is the down pipe so let's go ahead and chop that [Music] there we go one completed down pipe I mean who needs a muffler anyway right so that will sit down just like that also a shop light went out while I was doing this so I got to fix that this is bolted on ugly like but it will work for mock up also this heat shield will have to come off later as well now for the good parts first up we need to get rid of the stock Subaru flywheel I had to get out the impact and fire up the compressor luckily it didn't wake the baby and let me zip the flywheel right off [Music] [Music] now we can see where the adapter plate sits and according to Mick at buzzer ooh the plate will need a little trimming right here to fit the turbo ej20 - and a quick test fit confirms yep we do need to trim it right here a little bit I'm marking this with a marker and we'll start taking off tiny little bits at a time until it fits baby's still asleep so that's good [Music] clean it up a little bit with a file and let's check the fit it's still rubbing a little you can see this spot right here of this dirt and grease where it's hitting so we're just gonna take off a little more [Music] that fits like a glove knew and now we have a perfect fit so yeah check it out this is actually where I filed it's uh I went ahead and spent some time on it I mean you can obviously see where I did it but I Belleville this edge nice just like the other stuff is so it's like razor sharp and very smooth bad yeah that's uh that's golden we're gonna go ahead and stick this guy on there [Music] and I got to give another shout-out to buzzer ooh he is making this process a whole lot easier I'm basically just following along with his videos and I'll link those in the description but yeah this is a fantastic job shows you all the bolts where every years ago anyway he's been a huge help so check out his channel we're putting these four bolts in with a little blue loctite and torquing 240 foot pounds [Music] next we clean up the flywheel with some brake clean and make sure that it's perfect next up is the flywheel bolts with red loctite and 51 foot-pounds [Music] now at this time we should be putting a beefy clutch in this thing but again I got no cash for that so we're cleaning up the old one and slapping it back in this will be good enough for just getting around town if I don't push it and it'll also allow me not to have to push the bug around [Music] these guys only get like 25 foot-pounds now with the Volkswagen clutch installed on the Subaru engine we can now put the engine mounting studs in there's four studs here and one of them is longer than the others the long one goes up in the top left and I'm going to use red loctite on these to make sure that they stay put [Music] all right all the studs are in now we're gonna do a quick test fit you gotta get rid of that stud though that needs to go [Music] work now that those are done it's time to make room for the turbo we're going to get inside and I have most of the area cleaned up and ready to go and we're going to be cutting a hole right about here ish right where the turbo goes inside there's a bunch of gunk that I've been removing but it doesn't come off very easily so I'm gonna worry about that later and just go ahead and get my cuts done I need to do a quick test fit to see exactly where the turbo is going to hit and I can't get close enough so the deck plate needs to come off and this leads me to more Volkswagen wiring sloppiness the wiring doesn't disconnect from the light oh no that'd be too easy it leads down and splices in with the taillight wiring once that's disconnected we can pop the deck lid off and get the engine close enough for a test fit all right back to test fitting [Music] all right so it's still gonna come up about five inches but you can see the turbo right here and so this basically curry right here is where we need to cut and luckily my friend Mick over at bus aru has a video showing exactly where you need to cut this thing saving focus on this [Music] yeah so right there this is uh this is his video anyway I'm gonna mark that out the exact same way that he did cuz it worked perfect for him so let's go back oh I love that video in the description as well now we need a hole right here where there is none but that's a problem that can easily be solved with violence this is the fuel mm so make sure this is well out of the way [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] [Applause] [Applause] [Music] [Music] I also needed to make a few cuts in the car as well once that was done I pulled out the now scrap metal to make room for the turbo [Music] all right that holds cut looks pretty good I think that's about where I wanted it I went too far on a couple places right there and then really bad on the inside because I was trying to watch the camera angle instead of my cut which it's not a great idea but you can see right here I went too far as well yeah not as bad as I first thought but that should fit the turbo let's try it out [Music] I'm good Peter Holmes on the way because that's what is now that's gonna go [Music] oh okay nice some pretty good money around for the downpipe to sneak in there now for the next test fit and everything's looking good these two coolant fill hoses are hitting so we're gonna have to address that and the two heater hose fittings will hit slightly so they need to be bent down a little bit [Music] and then things like this brake booster line are going to get removed capped and relabeled so I don't forget what they are next I got some bolts in the down pipe to make sure that's secure they are definitely not the right bolts that came with this but I can't find those so these are working the wiring harness is his own project and we're gonna have to figure that out later we'll mount the engine first and then figure out exactly where we need to cut a hole to get the harness inside the car next up is lots and lots of test fitting the OEM heat shield on the downpipe isn't going to fit so off it goes I'll probably be doing a custom down pipe and custom heat shield anyway so no worries there and if the turbo hole needs to be bigger I know exactly where I keep the angle grinder so after another test fit I couldn't get the starter bolt Fassett ran through the problem of getting the starter in that pond so the the stud is going through there underneath the car but this literally can't thread because it won't line up with the hole and even if they did there's no way to turn it it's just it's too big to actually turn the reason for that is typically this has this really goofy a stud that goes to the other way so this really weird head on it and what that does is sits flat and then can't really turn once it's on there but that doesn't work when you're going this way you're trying to get a not down there because you literally just can't do it so did some googling found some other people that ran into this exact same problem and the solution is to grind away a big chunk of metal here so you can actually turn the turn the nut so that's what we're doing next and since I know where I hide the angle grinder we'll go ahead and fix it with that I took a lot of material off the starter and the nut looks like it'll fit now so let's try it out and good news that was a success [Music] you can see right here I can get the top starter bolt in and working and if you look behind that you'll notice that I need to get an o2 sensor in that down pipe before I put the engine in but we'll fix that later and there we go that engine is physically installed now all we need to hear it run is fuel and sorting out the wiring harness I wrestled and fought with the harness for a couple days and even got the courage to start breaking it down myself and that was a mistake I quickly got in way over my head so I need to ship it off to a pro and get it done correctly that cost about seven hundred bucks though which is about six hundred ninety nine dollars more than I actually have so for now the bug is getting put on hold up next we are finally upgrading the clutch on the Eclipse I can't wait [Music]

Channel: Velocity Labs

Views: 279,536

Keywords: ej22t, subaru, volkswagen, vw, bug, beetle, KEP, adapter plate, bugaru, turbo, boost, engine swap

Id: KSwFkXbEWS0

Length: 17min 58sec (1078 seconds)

Published: Wed Mar 04 2020