N1446' s Build Journal Post

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N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

N1446' s Build Journal Post

Post by N1446 »

>> This page is taking over the build page for a while as the EJ2.34t project is on hold.

Updates below
Last edited by N1446 on Wed Dec 23, 2009 5:55 am, edited 15 times in total.
N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

Post by N1446 »

  • Engine Removal Process < WorkS for Me

    Be sure to have a Wet\Dry Vaccume ready - you will need one for extracting fluids and catching leaks
    be sure to park on level ground
    For 5mt be sure the transmission is in _neutral_ ! !
    apply park brake

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  • -
    Tools -
    -
    *have Allen Key for the clutch pin cap
    have vice grips
    have metric wrenches
    have socket set 3\4" & 1\2" in metric & standard
    have socket wrench in 3\4" & 1\2 "
    *have socket wrench extentions 2"and 6" & a pivot adapter for bottom-end engine bolts and lower starter bolt
    have breaker bar for extending wrenches
    -
    have engine hoist
    -
    have 1 pump jack and 1 sissor jack
    have 1 pair of jack stands for supporting the front end off-ground , leaving room enough to roll around and use your elbows
    have protective lenses that do not fog / very important when working under the motor
    have methalhydrate for removing grease and cleaning bolts
    have many sets of industrial grade rubber gloves
    have respitory mask
    have carboard boxes
    have absorbant rags
    -
    STEP 1
    -
    Remove the Battery
    remove the Air Intake ; FOR TURBO : remove resonater and induction tubing
    Prop car using jack stands and pump jack
    OPTIONAL : remove wheels
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  • -STEP 2
    Drain Oil
    Drain Engine Coolant
    Drain Power Steering Fluid - optional
    de-pressurize fuel line

    -STEP 3
    remove the radiator
    remove the a\c core if so equipped

    - STEP 4
    undo the plumbing to and from the engine , be sure to have the shopVac handy !
    + A\C lines
    + radiator hoses
    + Oil lines \ hoses
    + Fuel line\ hoses
    + Vaccume lines

    -STEP 5
    undo the cabling attached to the motor

    -STEP 6
    undo the remaining wiring harness
    OPTIONAL : remove the AC compressor , remove the alternator , remove the power-steering pump , remove intake manifold-
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  • -
    -STEP 7 : Attach the hoist & chain-harness
    -
    STEP 8
    remove exhaust manifold
    remove starter
    FOR TURBO : remove turbo-downpipe bolts
    remove motor mount bolts
    remove 2 lower engine-to transmission bolts
    5mt remove clutch fork pin ; FOR AUTOMATIC : remove Intakle throttle body and remove torque-converter bolts at the Fly-Wheel
    remove 2 upper engine-to-transmission bolts

    -STEP 9
    apply minimal pressure to hoist to lift the motor off the engine mounts
    support the transmission with pump jack
    for stuck engine \ transmission use a blade and hammer at the joint

    STEP 10
    Breathe ; beer & Remove Engine
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Last edited by N1446 on Mon Aug 09, 2010 8:13 am, edited 10 times in total.
N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

Post by N1446 »

  • EJ25D installed in a MY'91 turbo Chassi + ECU
    I almost forgot ,, Installation is the reverse of removal - SSeriously though it not so bad
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  • 22T5mt items swapped onto phase 1 EJ25D engine
    -
    pwer steering pump
    alternator
    MAF
    flywheel cover plate - under-side
    -
    22T5mt manifold items swapped onto EJ25D engine
    -
    22t throttle body w\c position sensor
    22t idle air control valve
    22t ignitor
    22t purge control solenoid
    -
    22T5mt harness modification includes :
    -
    extending engine coolant temperature sensor clip to opposite side } on coolant crossover
    -
    extending temperature sensor clip to opposite side } on coolant crossover
    -
    knock sensor : switching connector style to EJ25D type, to accomidate the knock sensor on 25D
    -
    22t crank sensor : switching connector to EJ22t style to accomidate 22t harness
    -
    22t cam sensor : switching cam sensor to EJ22t style to accomidate 22t harness
    -
    neutral items \ universal fit both harness
    -
    injectors 1 2 3 4
    oil pressure switch
    engine coolant temperature sensor : needs harness extention
    temperature sensor : needs harness extention
    -
    EJ25D engine items remain
    -
    knock sensor
    crank sensor
    -
    EJ25D intake manifold items remain
    -
    injectors 1 2 3 4
    vaccume \ Intake tubing
    -
    OTHER PARTS NEEDED TO SWITCH TO EJ25 > 5mt
    ***
    5mt intake hoses
    ***
    UN USED PARTS AND SENSORS ON EJ25D > auto
    ***
    Tourque convertor
    EGR valve - i created a false valve gasket and bolted the EGR Valve back on over-top the false gasket with a high temp gasket sealer + capped plumbing
    EGR valve solenoid removed + capped plumbing
    -
    ***
    UN USED PARTS AND SENSORS ON EJ22T-5mt
    ***
    Charcoal canister removed
    Turbo exhaust manifold removed
    -
    Extra Parts Involved **
    --
    98 GT engine fans
    98 GT engine coolant overflow tank
- here is a video of the 25D start-up , there is no exhaust though the car idles fine without the o2 sensor
engine start
Image
Last edited by N1446 on Wed Aug 11, 2010 7:06 am, edited 3 times in total.
N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

Post by N1446 »

Soo this weekend between a 3000 word paper and a site report, i scurried up enough courage to pull the motor out and drop a new engine crossmember in right before work .. .. ...
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yeahh rrighttt

i prop'd the car up and whipped out the angle grinder and ripped out an inch off the crossmember.

may as well i just file it down a bit right ? - , and i do mean a bit

i m quite sure there is no loss of integrity here on the c-member

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+
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above is the exhaust installed ,
gasket maker and the gaskets that arrived with the exhaust make a great seal
-
i did have to remove the front swaybar for this exhaust to fit , headers are OBX for a '98-'05 impreza 2.5 RS
Image

not a huge deal , all this is temporary until the real motor is built

it sounds BeefY !
like chunk'i soup beefY!
next is finishing up on the rest , cut and paste sorta stuff
Last edited by N1446 on Mon Mar 29, 2010 7:05 am, edited 2 times in total.
N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

Post by N1446 »

Image

Vclip of 0-60, then 60-100^^
3/4 throttle
Quality is a bit rough.. the exhaust is yet to be sealed, so its a bit loud still.

next is plugs& wires
Last edited by N1446 on Fri Jun 10, 2011 8:22 pm, edited 2 times in total.
N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
SILINC3R
quasi-mod-o
quasi-mod-o
Posts: 2763
Joined: Wed May 30, 2007 6:11 am
Location: Charlotte, NC

Post by SILINC3R »

how much for those headers and do you have a part number available. thanks
Tony
90 LS Spec rio red sold
91 SS rio red R.I.P
90 Mazda Miata
2005 GT SWP
92ss satinsvoice wrote:LOL! that block was like F*** THIS! IM OUT!
mike-tracy wrote:Word. I'd love to get my hands on one of those trannies, but I just can't stomach the cost
N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

Post by N1446 »

part number # H10798
cost 299US on ebay right now
ebay item number # 200411172559 from seller : dialod
N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
SubaruNation
Fifth Gear
Posts: 3526
Joined: Wed Jul 18, 2007 5:07 pm
Location: Whammy!

Post by SubaruNation »

that sounds legit!

Nice!
Zach - Legacy Frankenstin
93forestpearl wrote:Keep up the good work. You'll never know what you are capable of unless you push yourself.
SILINC3R
quasi-mod-o
quasi-mod-o
Posts: 2763
Joined: Wed May 30, 2007 6:11 am
Location: Charlotte, NC

Post by SILINC3R »

so you said you had to remove the sway bar, is that permanent
Tony
90 LS Spec rio red sold
91 SS rio red R.I.P
90 Mazda Miata
2005 GT SWP
92ss satinsvoice wrote:LOL! that block was like F*** THIS! IM OUT!
mike-tracy wrote:Word. I'd love to get my hands on one of those trannies, but I just can't stomach the cost
N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

Post by N1446 »

SILINC3R wrote:so you said you had to remove the sway bar, is that permanent
as far as i can tell yess it is permanant, i have a turbo front swaybar and the bends colide with the pipe

non-turbo may be a different story
N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

Re: N1446' s Build Journal Post

Post by N1446 »

heay again here is the latest updates on the engine "upgrade"
I m tearing out the current EJ25 over the next two weeks for a younger prettier 2.5 from this 98 forrester S .. the red one
over the winter the legacy over-heat and threw a rod.. yess another one

Image

I also have some pictures of the finished exhaust after one winter, as you can see, the new headers fit to the existing chassi and also the cat-back portion is from a '98 legacy/outback, this is stock equipment on all the stock mounting hangars with a subaru mufler . IMO No easier upgrade than this for novices and a huge difference for off-the-line ie; no stumbling starts in place of the original equipment .

I' ll see if the front sway bar on the forester will fit the legacy now with the new headers -cause that would be sweet.

Image
N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
N1446
Second Gear
Posts: 279
Joined: Tue Oct 14, 2008 6:33 am
Location: Tantallon, NS

Re: N1446' s Build Journal Post

Post by N1446 »

Monday August 8th Engine Day
New Exedy Clutch and Engine Swap #2

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Below the reason engine #2 threw a rod
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With a side order of BBQ'd disk
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N1446 Brutus
91 Legacy SS 5mt 2.5GT Swap
Legacy GT Suspension, 16" Fozzy Wheels, 2.5RS OBX EL Headers, Gutted Mid-Pipe, Subaru Catback c/w AWD BABY !
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