Edit 2: After the engine went into the Legacy I was still having issues, so I had a Comp/LD test done and Cylinder 2 (or 4?) was low/leaking. The piston had a broken ringland and my Subaru Tech was very surprised it hadn't blown up completely. I Had the engine rebuilt w/stock pistons (budgetary restraints!), and then sold it as I'd moved on to the '04 Forester......so, it's very possible the engine was having the same issues while in the Forester and I just didn't think to check it out.
![Rolling Eyes :roll:](./images/smilies/icon_rolleyes.gif)
This thread may be updated w/the Legacy install on Page 2.
Yes, this has all been covered, but hopefully there's enough info in this one thread to consolidate some of the info on the board. If you see anything questionable - Speak Up - I don't want to add to the misinformation already out there.
First, I'd like to Thank Legacy777, Napphappy, Grayguy, All_talk, Matt Monson, PhyrraM, Skid542, Douglas Vincent and others on here for making this possible...I'm probably one of the least mechanically inclined members on here, but have managed to swap my '90 w/an EJ22T and now working on another Subie project all because of this Board.
My current project is a putting an EJ22T block w/the '96-'99 EJ25D DOHC heads into a '98 Forester, so the wiring in the pics is relevant for OBD2 cars (roughly '95-99) only, but all the plumbing should be the same (except for crossover pipe).
I'm also running JDM EJ20K turbo camshafts. They fit just like stock in the '97-99 USDM DOHC shim over bucket lifters (not sure about compatibility w/the '96 DOHC hydraulic lifters - HLA ).
I wanted to run a thinner headgasket to keep the CR up around 8-8.5:1. Based on a few threads over on NASIOC I read that others had used an EJ22e (non-turbo) HG. But when I got ready to install it I saw this:
![Image](http://lh4.ggpht.com/_TbG29PkJA2Q/S_S0yMJbBqI/AAAAAAAABQQ/nN3PYXXnmVU/s640/EJ22e%20head%20gasket.jpg)
And decided too much of the passages were covered, so I went ahead and just installed the EJ22T HG (pic below). For more info check this THREAD on NASIOC. Due to the risks of running too thin of a HG I'm NOT recommending this option, but if you do your research you can make up your own mind.
![Image](http://lh5.ggpht.com/_TbG29PkJA2Q/S_S0xNEYfWI/AAAAAAAABQM/seWZoXNB5DI/s640/EJ22T%20head%20gasket.jpg)
I decided to use the EJ25's water cross over since the sensors on the intake manifold would match the EJ25's harness (I'm not sure if this will be a good idea as it puts the 2 sensors in a very tight area where the turbo, etc. are all installed). This is ONLY for the EJ25 harness. Re-use your EJ22T pipe w/its matching harness connections or extend the wiring, if necessary (EJ22T on top):
I kept the pipe from the EJ22T that runs from the water pump to the Turbo's coolant tank, which I hope will will mount in the same location as my '90...we'll see. I did use a '92-94 EJ22T water pump. Others have used the non-turbo pump, but I don't know how it was plumbed:
![Image](http://lh3.ggpht.com/_TbG29PkJA2Q/TAx2MPzGjwI/AAAAAAAABSU/6COj6WP4OLU/s640/crossover%20and%20pipes%20%287%29%20%28Large%29.jpg)
To get the other heat/coolant line I modded the EJ22T's line. I cut and bent the tab, drilled the hole bigger and got lucky to reuse the oil galley bolt. Hopefully, it'll be close enough when installed (that wire loom cover was removed - just there temporarily).
Cut/Bent tab:
Here's a comparison of the coolant pipes that come from the water pump. The bigger diameter pipe is the EJ25 and although it follows the same path as the turbo's, it's for the heater hose - not the turbo coolant tank. As mentioned above, I ran the EJ22T's heater hose pipe from the water pump, under the head, like stock on the EJ22T.
EJ25 on bottom:
EJ25 on top:
IM installed:
STi engine mounts and exhaust manifold installed:
![Image](http://lh6.ggpht.com/_TbG29PkJA2Q/TAx2R6KeLYI/AAAAAAAABSs/xRWPYDFKNpU/s640/sti%20mounts%20and%20header%20%28Large%29.jpg)
EDIT: The PCV and Breather lines are two separate systems from what I've since learned....do not mix/match - keep 'em separate or you might create engine pressure issues.
Unexciting as it is, I got the PCV/breather hoses where I think they'll work- I'll clean it up after installed in the car. The PCV and breather hoses will all go thru the Helix catch can, which I've read is sub-optimum. {Don't do this!!>>>>}. The PCV and breather hoses should each have their own catch cans, if not going back into the intake {YES - 2 cans!}:
I ran the hose off the PCV out thru the pass. side of the IM....wait and see if that'll work w/the PS lines, et al:
Installed my 1st DOHC Timing belt. Used clamps to hold the belt in place on the pass. side and to hold the sprockets on the driver's side. Wasn't as big a deal as I thought it'd be. Used the marks on the timing covers and then counted the teeth - 3x - to verify. I had another 'gotcha' as the EJ22T's Tbelt tensioner pulley's bolt stripped out. Thankfully I had another EJ22e sitting in the corner. Since the bracket that the pulleys/tensioner attach to is replaceable, I just swapped in the other one. I could have also used the newer style tensioner and pulled the bracket from the EJ25:
![Image](http://lh4.ggpht.com/_TbG29PkJA2Q/TCGTUSgBfZI/AAAAAAAABVw/05LsdCb-pSs/s640/EJ25%20DOHC%20TBelt%20install%20%28Large%29.jpg)
Here's the plumbing for the turbo. I bought all the WRX piping from NASIOC members' listings. Oil drain/return, oil inlet, and coolant pipes (HERE is another other option and HERE is a good comparison of NA vs turbo heads). Since the NA heads don't have the oil return or coolant pipes threaded (just the bosses (?) for the cooland and return) I had a local Subie shop drill and tap those for me. I just removed the bolt from the head for the WRX's oil inlet line. The oil return is a TD04 coolant line bent and cut, w/the OEM rubber return hose connected:
Macgyver'd oil return line:
![Image](http://lh3.ggpht.com/_TbG29PkJA2Q/TCGTLkZbBUI/AAAAAAAABVE/0EHwxyfU2RE/s640/turbo%20oil%20return%20%28Large%29.jpg)
I used the WRX's turbo mounting brackets, as the EJ22T's didn't fit due to the DOHC oil inlet's location (it's on the end of the SOHC EJ22T's head). It wouldn't take much to modify it, but since I knew ahead of time (research!), I bought the plug-n-play option. I also used a WRX up pipe as I may need its EGT down the road (it's plugged for now):
EJ22T:
WRX 2-piece version:
![Image](http://lh3.ggpht.com/_TbG29PkJA2Q/TCGTJ1P2u_I/AAAAAAAABU8/iwCoc4dpNhA/s640/WRX%20turbo%20bracket%20%28Large%29.jpg)
If you've got any recommendations or need pics, speak up quick as I hope to get this installed this weekend!
![Smile :)](./images/smilies/icon_smile.gif)
Thanks,
Td