Got the van back after a long wait. Alan had a lot of other commitments so my poor van had to stay on the back burner.
Testing it now on the hills and it does maintain its speed when climbing. It is not by any means a racer but can maintain a reasonable speed when climbing the hills, not slowing traffic down. But the Subaru engine is so quiet I can not hear it when driving thus don’t know when to change gears. Need a rev dial on the dash. The fuel pump is/ was very loud with a constant whine but that seemed to be part of the package because you need to feed an injector system with fuel. The solution was a fuel tank as described below.
Performance differences climbing a hill before, the van would drop down to 19 MPH and you would be in second gear struggling to climb the hill, as described in Joker Project part 5.
Now I can Maintain a steady 70 kph and remain in 5th dropping to 4th gear on the steeper parts. This is the result that I wanted as it makes for safer driving no build up of traffic behind and dangerous overtaking to try and get past me before the next hill.
Got the van back a week before the CVRT was due so had to do a bit of paper work.
In Ireland you have to change the registration documents to reflect that you have changed the engine and under the rules you must present the vehicle to an SIMI registered garage to verify/inspect that the new engine is the actual engine in the vehicle. So I brought it to a local garage that had the SIMI registration. The engineer in the garage came out to inspect it and verified that everything was in order as it was. But when he saw the installation he immediately identified the engine as a EJ20 and said Wow it is such a perfect fit, so tidy.
I returned to the garage to collect the signed documentation verifying the engine replacement before going to the motor tax office. The garage owner who would be the final signature on the replacement explained that you have to be very careful and sited a case where a garage signed off an engine replacement on a vehicle that was later involved in a fatal accident. The replacement engine was from a stolen vehicle and this had repercussions on both the signature and the insurance. So just a word of warning Please ensure you have valid documentation from the donor vehicle.
It passed the CVRT or Doe with flying colours. The emissions are much lower than the previous engine so it is better for the environment and the fuel consumption is way better 27 vs 20 MPG.
Coming from a 1998 Subaru the ECU (engine control unit) uses Subaru Select Monitor 1 SSM1 protocol, so to see what is going on in the computer I purchased a cable from Evoscan which allows you to read the error check conditions on a laptop. But it does not allow you to reset them. Bummer. To reset the ECU you have to physically connect both the TEST Mode connector and Read memory connector to signal ground. They were just 4 loose connectors in the loom which we thought were not necessary so they got snipped off. Bummer.
To reset the ECU now, I have to disconnect the battery and short the two battery cables together to discharge the capacitors in the ECU.
Fuel pump noise.
The fuel pump was very noisy and the eventual fix was a fuel tank replacement with a VWinjection fuel tank that has a 12 mm outlet to the fuel pump. The original tank had an 8 mm outlet to the pump which was sufficient for the carb 1.9 boxer engine but not good enough for the injection Subaru engine.