I purchased a used 2001 Subaru Impreza 2.2L naturally aspirated engine, along with ecu, full wiring harness (engine, engine to ecu, and dash) from a local salvage yard. I still need to acquire an altenator, mass air flow sensor, A/C compressor, and ignition system eventually along with various other bits and pieces. The engine was compression tested at 185 psi on all four cylinders and ran well when pulled and had 48,000 miles.
Total Cost $1,000
This is the phase 2 model with OBDII and clocks in at 145 bhp at 5600 rpms and pulls a stout 149 ft-lbs of torque ate 3600 rpms. That is double the stock 70 bhp that the aircooled engine provided!
The two eyeing each other; its like a first date...
Here is a shot of the wiring harness (I get stressed everytime I look at this mess):
And here are the other parts that will need to buy:
Vanagon Rear Engine Mount Cross Member = $20
Custom fabricate or RJES
Throttle Body Reverser (eng -->1999) or
Induction Manifold Reversal Kit (2000--> eng) : This you can do yourself by flipping the manifold 180* and the flipping the engine wiring harness back 180* so the firing order on teh enjectors remains in the correct order.
Kennedy Engineered Products
Adapter, flexplate and bolts = $480
The adapter is what allows the Subaru engine to bolt to the VW transmission. Since the two parts weren't meant to fit together orginally, an adapter or spacer is placed between the two and has appropriate bolt hole alignment on one side to fit the engine and a different bolt hole alignment to fit the transmission. Note: this picture from Kennedy's site shows a fly wheel for a manual transmission instead of a flexplate for an automatic transmission (that I will need).
Small Car Performance
Subagon Parts Kit - Automatic Vanagons = $1,495
Hall effect speed sensor kit = $50Subagon 5qt aluminum oil pan = $330
The shortened oil sump is not necessary, but the stock Subaru oil sump pan hangs pretty low, so if you don't replace it, chances of catching road rocks or other unwanteds compiles. It also reduces approach and departure angles on steep grades or (goodness forbid) 4x4 roads. Shortening the sump while maintain stock oil capacity is the name of the game.
Vanagon stainless exhaust with OE cat = $585
Interface Board = $65
This list should get me started down the road. Most important to the conversion right now is the engine mounting bar, the adapter and flexplate, and the reversed induction manifold. That will allow me to get the engine installed and mounted to the transmission. Then all the small and hard steps begin to make it function appropriately.