The SLODRIVE '92 SS Build (Now with Dyno Sheet!)

[SLODRIVE]

There's plenty to do even without parts, so this morning I started re-routing the heater pipes. They just won't work where they are...


I didn't want to use the EJ22 coolant crossover since the coolant pipe to the water tank wouldn't mount correctly on it. So, I removed the pipe from the EJ20H crossover, dug up the old EJ22 coolant pipe from the water pump, and started measuring, marking, eyeballing, cutting and welding.

A little later...(Look closely, you can see two welds)



I can even still get to the knock sensor, as luck would have it:


I decided not to weld on the nipples to feed the throttle body since I won't be running coolant through it. I'll have the other pipe done by later this afternoon.

[SLODRIVE]

And here we are, a little chopping and splicing later:



Painted and ready to go...




One problem out of the way...Time to play with the intake manifolds.

[SiCkSTi04]

nice build so far keep it up.

[SLODRIVE]

I'm an idiot...as soon as I started looking at the intake, I realized that the IAC needs coolant to run through it...thus I need nipples on the heater pipes. So, I pulled them back off, cut two nipples off of some old pipes, drilled holes, welded and re-painted, bla bla bla...

Better now.

[92ss satinsvoice]

run wit you bring. you got this DOWN! slick shit, keep it pushin.


(im drunk) sorry for the bad words.. ROCK IT!!

[Legacy777]

Nice work! I really need to learn how to weld....

Whaddya mean? That twin-turbo setup is a direct fit...




into the trash can! I have a TD04 and an FXT TMIC that I'm going to use.

I got a good chuckle out of that

[SLODRIVE]

Thanks for the compliments all. I still have a long way to go though.

I did some more fiddling around in my spare time this week:

I finally got to work on the intake manifold. First thing I did was strip the wiring harness off and install the EJ22 harness which was no problem. I also found a spot for the purge solenoid.


My biggest challenge so far has been getting a throttle body to work with this setup. First, note the difference in inner diameter: the EJ20H TB on the right has an ID of about 54mm; the EJ22 TB on the left, about 60mm. Big difference! The hole in the intake plenum matches the larger unit though.

The EJ22 TB rotates in the opposite direction of the EJ20H TB and thus the linkage won't directly work, since I'll have to flip the EJ22 one 180 degrees to clear the IAC. However, the EJ20H unit (on the right) has a totally different TPS setup which I can't see easily adapting to the EJ22 ECU and harness. See below:



To make matters worse, the EJ22 throttle body has a large vacuum port on the backside that would be uncovered when mounted upside down. Also, the TPS and the linkage both hit the intake. AGH!


After some reading, I found the solution on NASIOC, from one of Douglas Vincent's posts no less! The next day, I scored a piece of 1/4" aluminum, traced the TB gasket out, and then used a hole saw, the drill press, and the sawzall to make this spacer.


I then made two new throttle body gaskets, since nobody had any locally.


With the spacer, the linkage and TPS now clear the manifold, and the port on the back is sealed up. Still room for the PCV and the line to the evap solenoid. I still have to figure out what I want to do with the throttle cable, but that shouldn't be too bad. I also cut the coolant pipes off of the TB.



Next item...a coil bracket. All I had was some angle iron at that moment, but it welded up okay I guess. It mounts with the TB bolts and rests on top of the metal lines. It may be ugly, but it's solid as hell!

[stipro]

That looks really good, very impressive

[beatersubi]

Nice work. Sawzall fabrication FTW!

[GodSquadMandrake]

Very interested to see what you do with the EJ20H!

[PhyrraM]

Nice work so far. I think I'm going to reference this thread in the DOHC head installation thread. It will be good for folks to see just how much work goes into modifying one to fit, and can then decide if it's something they can attempt.

Interesting to see an EJ20H with the metal cam sprockets. Usually you only see those on BC/BF EJ20Gs. Even early '93 WRXs had the plastic ones.

[SLODRIVE]

Nice work so far. I think I'm going to reference this thread in the DOHC head installation thread. It will be good for folks to see just how much work goes into modifying one to fit, and can then decide if it's something they can attempt.

Interesting to see an EJ20H with the metal cam sprockets. Usually you only see those on BC/BF EJ20Gs. Even early '93 WRXs had the plastic ones.

Thanks. That's very cool of you to reference this thread...I'm posting all these pics so others can reference them anyway. I realize there's not too many photos of this stuff.

I also have to admit that I'm doing some of this the "hard way". I'm sure I could have sourced coolant pipes and an EJ25 intake at the salvage yard and just bolted everything together, although it wouldn't have been as fun for me!

Just curious...Are you saying that EJ20H motors usually have plastic gears? From the looks of it, the timing covers had never been off the motor before I got ahold of it.

[PhyrraM]

Just curious...Are you saying that EJ20H motors usually have plastic gears? From the looks of it, the timing covers had never been off the motor before I got ahold of it.

Yeah, *generally* anything beyond '93 will have the plastic gears. But Subaru is infamous for mixing it up a bit. There are tons of "exception" cars. Many people (I would consider knowledgeable) seem to think that Subaru liked to use up stock, even past the supposed switchover point.

Either way, the plastic gears are lighter. But, the metal gears are cooler. Especially if you run without timing covers.

[GodSquadMandrake]

Yeah I just got a set of the plastic gears and I am excited to try them out. They are WAY lighter and it's 4 of them. I'm sure it'll make a difference in engine response like having a lightened flywheel or something.

What I really want to see is how you install that twin turbo engine in your left hand drive car.

[Legacy777]

Again, nice work!


The later year TB's had that vacuum port sealed off, but it sounds like you got it taken care of.

[dropdfocus]

This is a mucho sick build!!!! Thanks for all the tons of info so far! I have EJ20G heads to go on my "built" motor when I get to that point and this has given me heads up on quite a few things (ex: thottle body issues).

[GodSquadMandrake]

Watch out for gaskets too. The only place I could find the valve cover gaskets and valve cover breather gaskets was Rallispec and they had to import them from Japan which took over a month altogether.

[dropdfocus]

Also good to know!

[SLODRIVE]

Watch out for gaskets too. The only place I could find the valve cover gaskets and valve cover breather gaskets was Rallispec and they had to import them from Japan which took over a month altogether.

The valve cover gaskets aren't tough to find at all for this EJ20H...they're the same as an early '96 USDM EJ25. The Fel-Pro part number is VS50555R, you should be able to get them anywhere. In fact, every other seal and gasket is the same too, as well as the timing kit. If you tell the parts guy it's an early '96 Outback 2.5 liter, you will be all set, except for the water pump (any USDM WRX/STi pump will work) and oil pump (again, WRX/STI, etc.). In fact, I'm using the used-but-good water pump and oil pump from the '04 STi motor I built, and some of the (new) leftover gaskets/seals will fit as well. Bonus!

What I really want to see is how you install that twin turbo engine in your left hand drive car.

Aha, you didn't read some of the posts above! Again, I never planned to use the twin-turbo setup. Search around and you'll find that Subaru's TT setup is a bad choice, and not just because it DOES NOT FIT LHD CARS.

That's OK...I'll show you the mock-up.


I used the manifold and up-pipe from the '04 STi, which incidentally are IDENTICAL to the '92 parts...they were just cleaner, lol. Between the two manifolds and the TT manifold, I managed to get a whole set of heat shields as well. I cut the upper shield from the up-pipe because it was loose. I also cut a tab off of the EJ22T up-pipe bracket to clear the head.

At this point I'm using this TD04 from a USDM WRX ($50 on Craigslist) that seems to be in great shape. The oil feed line from the EJ20H's RH turbo fits perfectly, but I did have to swap the oil return pipe on the head for the EJ22T unit, which lines up with the TD04 perfectly. The turbo coolant lines are all plumbed up in these shots, up to where the coolant tank sits.

[dropdfocus]

Sweet, the info keeps getting better & better!!! Thanks!

[beatersubi]

Is that a levitating cooland resevior?

I used the manifold and up-pipe from the '04 STi, which incidentally are IDENTICAL to the '92 parts

If you order a EJ22T uppipe from a dealer, the p/n is superceded by the STi part. Fascinating, I know.

[GodSquadMandrake]

The valve cover gaskets aren't tough to find at all for this EJ20H...they're the same as an early '96 USDM EJ25. The Fel-Pro part number is VS50555R, you should be able to get them anywhere. In fact, every other seal and gasket is the same too, as well as the timing kit. If you tell the parts guy it's an early '96 Outback 2.5 liter, you will be all set, except for the water pump..

I think the EJ20H heads must be something like the WRX EJ20G heads then. I have the 89 JDM Legacy EJ20G heads and they are different. One side has a completely square valve cover gasket, and the other side has a notch cut out of it. It looks like yours both have that notch cut out.

My setup is kind of opposite of yours. I used EJ20G heads, but an EJ20H intake manifold. It was either that or the USDM EJ25 intake manifold. The EJ20H manifold has much bigger runners and it doesn't have the EGR valve stuff. The only problem is it's RHD so to make it fit I had to flip my throttle body upside down, and consequently the TPS couldn't be plugged in because the plug part was facing the castings on the intake manifold. So I took the TPS apart and flipped it too. Routing the IAC valve will be interesting because it's on the wrong side of the manifold but that shouldn't be a problem because so is the BOV on all WRX's. Overall it went together quite nicely and I took the time to port out my throttle body and knife edge the butterfly in there.

Aha, you didn't read some of the posts above! Again, I never planned to use the twin-turbo setup. Search around and you'll find that Subaru's TT setup is a bad choice, and not just because it DOES NOT FIT LHD CARS.

That's OK...I'll show you the mock-up.

Wow that fits together amazingly well. Looking good man. I wish I would've just got the whole EJ20H setup like you did. I think you got better heads and it isn't that hard to turn it into a single turbo. My big complaint with the Legacy EJ20G heads is the combustion chamber is so huge your compression just sucks. I'm at 7.66:1 which is less than stock and I want to run E85 so I need to be increasing compression not decreasing. This is also for a Rally car with a 34mm restrictor on the turbo which means I am limited on airflow. Compression is way more important than boost numbers because my turbo won't ever be able to hit anything over 20 PSI and my motor falls flat at 6,000 rpm. I'm thinking of building up a set of EJ25D heads on the side and getting the valves worked and the combustion chambers coated.

[SLODRIVE]

Making progress...

Before I bolted the exhaust manifold on, I pulled the oil pan with crossed fingers...this would be the make-or-break point on whether we run with this long-block. I was pleased to find that everything was nice and clean, and no debris in the pan. That's just droplets of oil in the pickup. I Three-Bond'ed it back on and continued.


Random shot...JDM oil filter, yo!


Once the bottom of the engine was ready, I moved to the front.
I got some parts from the dealer:cam seals, oil pump o-ring, intake gaskets, t-stat, and turbo gaskets. I looked up everything as an early '96 EJ25 (except turbo gaskets, duh!) and all the parts were spot-on. I already had the crank seal, waster pump gasket and other misc. stuff as leftovers from the STi build.


First I removed all the timing components, inner timing covers, and cam seals. At the same time I plugged the hole for the turbo oil feed line at the front of the LH head. I was feeling lazy, so I just used a steel spacer with the old banjo bolt and new washers.


After replacing all 4 cam seals, I then removed the oil and water pumps and cleaned the surfaces. No debris or other unpleasant surprises here.


I re-used the 10mm oil pump from Rob's STi. It was from a Cosworth long block with well under 15k miles, so I disassembled it to check it, cleaned and bolted it on.


Same story with the water pump...low-mileage EJ257 unit in great shape. (When the EJ22T shortblock's done, it'll get all new stuff...this stuff I'm using now only has to live for a few months, I hope.) here it is installed with the new t-stat, about to get a water outlet.


Installing the cam sprockets after bolting on the inner covers and dipstick...I'm digging these metal gears right now. Makes it easy to torque the bolts.



For the timing kit, I went Ebay and got a great deal. The bearings are all GMB, which have done okay for me in the past. The belt came in an Armor-Mark box...I have no clue who made it. At least it's German made, so maybe it's a Continental. Either way, it'll live for a few thousand miles until I put a proper Gates belt on the EJ22.


Timing kit, etc. all installed, ready to cover up:


...And there we are, front of the motor done!


Installing the intake manifold will be next. This part had been bothering me for a little while. There isn't much room behind the intake runners for a 90 degree turbo inlet, so I started looking at a WRX-style inlet under the manifold. The problem with the USDM inlets are that there's no good provision for the IAC hose...hmmm. I was stumped to the point where I was about to hack/splice/ghetto my own setup from the EJ20H inlet, and who knows what.

Then I found exactly what I needed from an Ebay store located in China. Unbelievably, It only took three days to get this, the only aftermarket part so far...


...a silicone inlet for a '96-98 WRX EJ20K. The elbow near the front will line up perfectly with the IAC pipe in top of the intake, and I also got a connector for the MAF. Both items came in at under $120 shipped, and are 4-ply reinforced to boot. Also nice was that they're available in black...I'm not a fan of bling, especially on this ugly turd.

Stay tuned for more fun!

[dropdfocus]

Is it wrong that I've been drooling as I read through this and stare at the pictures???

[GodSquadMandrake]

I've been trying to think up a solution for my inlet boot too. Nice find! So that floppy dong on the 90' bend is for the IAC? And the big nurple on the other end is for the recirculator valve?

Why didn't you put the inner timing belt cover on the block?

Whats wrong with the plastic gears? I was going to use those as they are a lot lighter.

It's looking good man! You are keeping me highly motivated for my engine. I'm still hunting down a 06-07 WRX intercooler, and a perfect power 6. I got the wideband, fuel pump, and fuel injectors.