Maciek's 2.36L Turbo Build (and boom goes #4 rod bearing!)

[SCOOBYurabus]

Maciek’s 1991 2.35L Turbo Legacy (updated 7.14.10)


Hi, I’m Maciek and have decided to document a 2.35L stroked turbo motor build.

The goal of this build is create a reliable and conservatively tuned daily driver Turbo Legacy capable of 400ftlb/350hp while remaining loyal to the ej22t platform. The manner, in which I chose to achieve this goal, is through a 2.35L DOHC turbo motor.

The car I own is a 1991 Legacy Sport Sedan in pearl white. I have owned this car since 2007 and it is my daily driver. Here are some pictures of the car.









It is running the stock long block with 240K miles. The car makes 270ftlbs and 240hp at the wheels. With the high mileage motor, restrictive 22t heads, and maxed out TMIC; I have decided to build a proper motor for the Legacy.

Following is a list of modifications I have already made:

Engine:
VF39 turbo
06 WRX TMIC
550cc STi fuel injectors
Walbro 255 fuel pump
92 Legacy NA fuel rails
Invidia bellmouth 3” DP
Borla Hush 3” CBE
Coffee mug intake mod
JC Sports cone filter
TurboXS BPV
NKG Iridium spark plugs
Diamond coilpack
8.5mm Magnecor spark plug wires
Lightweight pulley set
Exedy lightweight flywheel
Exedy Stage 1 Race clutch
Group N tranny mount
Group N pitch stop
WRX shift linkage
Hallman MBC
Manual FCD
PP6
Innovate LC1 wideband O2
IC sprayer nooozles
WRX Coolant Reservoir

Suspension:
KYB AGX
GC coilover kit
18-22mm Whiteline RSB
22mm Whiteline FSB
Perrin F/R endlinks
STi trailing links
02 WRX rear lateral links
SimplySubie fender braces
STi front strut tower brace
OBX rear strut tower brace
ALK- 99 Outback bracket with Poly bushings
17” JDM BG5 wheels
215/45 Yokohama S-Drive

Exterior:
02 WRX hood scoop
94 GT sideskirts
RS Liberty rear skirt
30% tint
96 GT projector driving lights
Blinking corner lights

Interior:
Nardi steering wheel
98 GT shift knob
STi shift boot and trim
98 Outback leather heated seats
GC8 A-pillar triple gauge pod
Autometer ES Series Boost gauge
Autometer ES Series Oil Pressure gauge
Innovate AFR gauge
WRX aluminum pedals


The motor build and ECU, wiring and installation, should take me 18-24 months. The motor swap should take place in Summer-Fall 2011. The current motor needs to last that long without any problems….last thing I need is a spun bearing 6 months out from a whole new motor.


I set up 8 sections where I will be adding and updating information throughout the build. When I post updates, I will note on each section the last date of edit.

I have decided to break the build into the following categories:

SECTION 1 – Short Block
SECTION 2 – Heads
SECTION 3 – Intake Manifold
SECTION 4 – ECU and Wiring
SECTION 5 – Transmission
SECTION 6 – Suspension / Brakes
SECTION 7 – Body
SECTION 8 – Miscellaneous


I will comment on the progress of the build throughout the thread, but the bulk of the information will be compiled into the following 8 sections and kept at the fornt of the thread for easy access.

can i buy this i live in colorado man shoot me a text at 303-710-0112

[SCOOBYurabus]

can i buy this dude i live in colorado shoot me a text man 303-710-0112

[macipusy]

I am currently swapping my 91 SS over to a 93 TW....so I will be selling the stripped down sedan at some point. It will still be 300 wtq, E85 tuned car running on a Haltech standalone...but s a lot of the mods will be transferred to the wagon.

I have a possible future buyer at the moment, if it falls thru I will let you know. It will not be less then $3500...and any time soon.

[macipusy]

OK! So I have a bunch of updates to write about. 2 big projects happening at the moment. I have been taking photos of everything, and will post them up eventually once I sort and edit them.


The first project is the continuation of the ej235t build for my V6 STi RA (2001 Impreza RS 4dr) swap. The long block is all together (ej22t case halves, CP custom pistons, Eagle forged rods, 04 STi crank shaft, ACL bearings, ej22t stock HG, ej205 heads with STi valves, Gates racing timing belt)

I have been working on modifying the WRX engine harness to retain only the necessary sensors/actuators and relocating the main harness connectors from near the battery location to above the transmission bell housing (closer to the stock RS main plug location). The AEM oil pressure gauge and the Haltech IAT sensor are the last components to add to the wiring harness before I encase and seal it.

The Injector Dynamic 1000cc injectors are installed in the WRX manifold. The new ID1000 connectors have been spliced onto the wiring harness.

Just received the GrimmSpeed ceramic coated up pipe, so I can finally mock up the turbo location. I will port match the headers to the gaskets at the head port loations.

I sandblasted the oil pan and had it powder coated clear. I will be assembling the oil pan and pickup this week.

Forester oil cooler assembly is on the car.

I have mocked up the STi TMIC with the silicone intake plumbing and the GrimmSpeed phenolic spacers. Everything fits nice.

I have installed the STi coolant crossover pipe, which leaves enough room in front of it to utilize the crankcase breather vent location on top of the block. I'm in the process of thinking about the catch can and the whole PCV system in general.

Like I said....I have been taking pictures and will post them eventually.

[macipusy]

The second big project is swapping all my stuff from the 1991 SS to my new 1993 Touring wagon.

The back story on the wagon (2 year long nightmare): My brother owned the turbo wagon for 3 years as his winter commuter....he has a rear wheel BMW and lives in CO. One day he decides he is done with the car and wants to sell it. One of my 'friends' (also a guy off this forum) shows interest. He wants to make payments and I know he is not the best with money, so I make him sign a contract for $1500 and he takes the car. Makes a few payments then disappears. I find him a year later and threaten to sue if he doesn't pay or return the car. He says the motor blew up. Few more months go by and I finally repo the car.

Under the hood I find a big td-05 16g turbo on unlimited boost pressure (completely open wastegate system) and stock injectors.
He melted a hole in the #4 piston and kept rodding it. Forced all the oil out the breather vents and spun and melted #1 crank bearing....luckily the hole in #4 limite powder and prevented from shooting the rod thru the block. Block is good for a bore and hone. The heads had chunks missing from detonation....looked as if someone took a chisel to the head and top of piston. On top of that, the fuel pump relay was fried.

So I had to swap over a junkyard motor I had sitting in my garage for 4 years. Turned out that most of the metal coolant lines were corroded shut and the car was overheating....took weeks to troubleshoot. With all the time it took to recover and rebuild the car, I decided to keep it and get rid of my sedan. I don't need 2 sedans (91 SS, 01 STi), plus the 93 wagon has mint condition interior and exterior (one of the nicest and cleanest I have ever seen for that age, EVER). Now I can have a quick and nice wagon to haul my mountain bikes


Fast forward to 2 weeks ago. Got all overheating issues taken care of and modded the car a bit. Currently I am running it on the td05-16g on wastegate boost pressure (~7psi)....I verified AFR's with a tailpipe wideband O2 unit. Installed the 08 FXT TMIC with all new couplers. Moved over the 2.5mm plug wires, diamond coil pack and light weight pulley set from the 91 SS. Installed the 05 WRX seats with a V7 WRX MOMO steering wheel...it looks sharp!!!

The V4 STi struts/springs are in and front and rear whiteline sway bars as well. I still have to move over the ALK, strut tower braces and fender braces.

I will be installing the 94 GT wagon sideskirts and the 98 GT rear wing. I need to find a 94 GT wagon rear lip....anyone have one?!

Already rolling on the JDM BG5 wheels 17x7 gunmetal with 215/45R17 Yokohama S-drives.

I am also thinking of swapping over the 91 front end to the wagon....not 100% decided yet.


SO....I have been pretty busy and I will post pictures of the wagon too!

[Dominator]

Wow, lots of progress. You say you have pictures. Can't wait to see them!

[macipusy]

OK!!! I am posting a link to the build pictures of the short block from last November. On page 3 there are some pics of ej20h heads being bolted to the block....these are not being used anymore and ej205 heads/manifold/top feed rails and injectors are the replacements. I broke a cam retainer bolt during the install and had a revelation during removal to get rid of the phase 1 heads for the better flowing USDM WRX setup.

Here is the link to my friends page:

http://mycoloradophotos.com/PGS/maciek/235build/

ENJOY!!!

I will start downloading pics off my iPhone and start to slowly post them up.

[macipusy]

As promised, here come the pics!!!!

First are shots of the 2001 Impreza RS which will be receiving the build ej235t motor.


2001 V6 STi inspired Impreza build




4 piston front brake swap - Power Slot slotted rotors, 06 WRX front calipers, Goodridge SS lines, Hawk HPS pads




2 piston rear brake swap - Power Slot slotted rotors, 06 WRX rear calipers, Goodridge SS lines, Hawk HPS pads, Kartboy adapter brackets




Finished shot of the front

[macipusy]

Modifications to the 2001 Impreza RS thus far:

Engine:
K&N cone air filter mounted on TB under a functional hood scoop
V6 STi hoodscoop splitter with IC sprayer noozles
LW underdrive crank pulley

Suspension:
H&R coilovers with Bilstein dampeners
Group N F/R top hats
20-24mm Whiteline RSB
Perrin rear endlinks
06 WRX 4/2 pot brake calipers
Goodridge SS brake lines
Power Slot slotted brake rotors
Kartboy rear caliper adapter brackets
Cusco front strut tower brace
04 STi BBS wheels 17x7.5
225/45/R17 Hankook Ventus V10

Exterior:
V6 STi clear corner lights
V6 STi tail lights
Ebay clear side markers
V6 STi grill and pink I-badge
V6 STi rear spats
V6 STi front lip
GC8 coupe wing
20% tint

Interior:
V6 STi Momo steering wheel
V6 STi EDM gauge cluster (160mph and 7K redline)
V8 STi F/R seats
GC8 center triple gauge pod
AEM boost gauge (30inHG - 35psi)
AEM oil pressure gauge (0-100psi)
AEM fuel pressure gauge (0-100psi)
AEM wideband O2 gauge (digital display)
Single gauge pod for steering cluster mounting
WRX aluminum pedals


Stuff I have but still need to instal:

JDM GC8 aluminum control arms
Whiteline control arm front bushings
Whiteline ALK
Whiteline roll center kit (ball joints and outer tie rod ends)
Whiteline 22-24 FSB
Whiteline front endlinks
04 STi steering rack
L&E steering rack adapter GD to GC
Whiteline steering rack bushings

And of course:

ej235t DOHC built stroker motor with td06-20g TEC turbo and ID1000 injectors
Group N engine mounts
STi TMIC
Haltech Platinum 1000 ECU
05 LGT 5mt (4.11FD, 04 STi axel stubs, GC speedo gear, new main bearings, 45K on gears/syncros)
shifter bushings F/R
Group N transmission mount
Walbro 255 LPH fuel pump

Still need to buy:

Clutch
Flywheel

[macipusy]

Now for more engine build photos

All short block build photos are here:

http://mycoloradophotos.com/PGS/maciek/235build/


short block ready for ej205 DOHC heads


cam shot of the ej205 head


another


valve covers on....I Fujibonded them for some extra anti leak action


shiny valve covers


DOHC water pump hard lines. Oops wrong crank timing belt pulley


Uhhhhh so pretty....Gates blue racing timing belt. And the right crank timing belt pulley


ready to pull the pin

[macipusy]

GrimmSpeed phenolic intake manifold spacers....the short 3mm ones. Still need gaskets on both sides of it.


Timing belt area all buttoned up. Intake runners with TGV deletes on for test fit


STi coolant cross over pipe and WRX coolant reservoir to water pump hard line


ID1000


injectors installed in the manifold


shot of the clearance between the STi cross over pipe and ej22t crank case breather hole


from the side

[macipusy]

Let the wiring harness modification begin


more stuff test fitted


from the back


and with the STi TMIC

[macipusy]

Stock ej22t headers...gasket port matched


with this bit...5 minutes per hole then polish


GrimmSpeed up pipe and TEC td06-20g turbo test fit


front of turbo...see a stock ej22t HG poking out?


Oil pickup and baffle plate installed...nice and clean


oil pan is on...it is soda blasted and clear powder coated. Forester oil cooler installed.


Super shiny thermostat cover with block heater behind. WRX DOHC oil dipstick with new o-rings is on as well.


Underside is done! only waiting for GrimmSpeed cross over pipe...on back order
Headers are painted flat black. Group N engine mounts installed. Notice the Greddy magnetic oil drain plug...fricken magnet is so powerful, it is hard to get it in the hole without it getting sucked to the oil pan body.

[macipusy]

Last night I calibrated the STi water temp sensor for the Haltech ECU install. I took 5 resistance readings over a fairly large range of temperatures ranging from 32 degrees F to 205 degrees F. I think I have data points for 32, 80, 180, 200 and 205 degrees F. I would like to add more data points between 32 and 80 degrees F, as well as, between 80 and 180 degrees F, because the graph plot is not linear but exponential in nature.

I should be able to finish up the wiring harness this week and start the plug and play portion of the ECU install in the passenger floor board ECU location. I have been working on my wiring strategy....now just to splice all the wires. Haltech ECU to RS bulk harness (plug and play portion) and RS bulk harness to WRX engine harness (hack the engine bay portion)

I only have a few miscellaneous items on the block left to do....TB coolant lines and some remaining PCV hoses and crank case breather fitting.

Hope to be pulling the stock ej251 out of the Impreza in 3 weeks! Then pull the cross member/steering rack and control arms and go to town cleaning the engine bay area. After it's all clean, I will do the engine bay portion of hacking the Impreza bulk head harness. Then engine drop in time!!! (ej22t cross member, 04 STi steering rack, JDM aluminum control arms, Whiteline FSB, Whiteline ALK, and the ej235t motor)

I might do the 05 LGT transmission swap then as well....if I get a chance to make a decision and purchase the clutch setup.

[CAV3MAN227]

-So pretty. ...lost for words!

-Joe

[Legacy777]

Looks good!!!

Regarding the coolant temp sensor. It should be a standard NTC resistor type sensor. I'm not sure if Haltech has a drop down for it, but I have been using that type on my Link setup. It's a few degrees off my calibrated EGT at first startup. I could probably pull it and get closer, but I'm not sure it's a big deal.

[macipusy]

I have been finally working on the motor every night on the push to the finish. I am planning on pulling out the ej25 out of the RS next Thursday. Then I need to do some wiring harness splicing for the Haltech and all the gauges, and then the motor can go in. As of now, the turn the motor on date should be around mid November. I am super excited, it's been 4 years since the conception of the theoretical idea of this particular design path to the ej235t.



GrimmSpeed exhaust crossover pipe finally showed up. Had to shorten the bracket on the Forseter oil cooler coolant line to clear the crossover pipe. It was off of a n/a Forester, the reason for the interference.



Bottom side all finished up.



I then finished up wrapping the wire harness and repositioning the main engine harness plugs.



Mounted harness to underside of manifold using insulated pipe clamps.



Close up of mounting brackets.

[macipusy]

I then mounted the turbo and intake manifold, and started finishing up all the coolant, oil and vacuum lines....not all done yet, but a big push.



Close up of turbo area



Oil and coolant supply are done

[macipusy]

I then started to mock up the center triple gauge pod.



But this showed up and distracted me.



Couple of shots of the mock up....still primer gray

[Legacy777]

Looking good! Keep up the good work.

[macipusy]

The stage is set. Impreza is on jack stands. I pulled the radiator, alternator, battery, wiper fluid reservoir last night. Pulling the ej251 tonight along with the exhaust, crossmember and steering system. I will then need to scrub the engine bay. Once clean, I can start hacking wires near the firewall for the engine harness splice.

I'll snap some pics of the engine pull tonight.

[macipusy]

Did a big push last night, but didn't take any pics yet. I'll snap some today or tomorrow.

I cleaned the whole engine bay....except the stock transmission. That is already planned to be ripped out in March, so I refuse to clean it. It's kind of an eye sore within the spotless engine compartment.

I assembled the JDM aluminum control arms with Whiteline ball joints, ALK and front control arm bushings. I cleaned them to a near mirror finish.

I centered the '04 STi steering rack by measuring reference points at full left and full right, then splitting the difference. I want the steering wheel and rack to line up as much as possible during the install.
Then mounted the rack to the turbo Legacy cross member, with Whiteline steering bushings and outer tie rod ends. Also installed the GC to GD steering coupler.


So, this car is going to feel so much different, in addition to the extra power. I'm super stoked for the quicker ratio rack and all the extra stiffness.

[macipusy]

My brain is toast and I am completely exhausted! I felt like I was in one of those reality car build shows, the ones where a team has 72 hours and needs to build a race car....blah blah blah all nighter blah blah. Wednesday worked 6 hours, Thursday 12 hours, Friday 13 hours and Saturday 10 hours and then we fired it up. I had a team of 4 talented friends join me for the final days.

Only things that had to be corrected once I cranked it over, was a little leak on the fuel line (tighten the clamp) and a leaky banjo on turbo supply (used turbo had a small gouge in the housing where the copper washer sits)...we just used a copper washer with a wider shoulder and no more leak. I would say for the magnitude of the project, those setbacks were not significant at all.

I will post progress shots once I rest a little, but here are a few.







And some of the suspension bits that made their way on during the swap....JDM control arms, Whiteline roll center kit, Whiteline front control arm bushings and ALK, along with the ej22t cross member and 04 STi steering rack.

[Aki]

Awesome build man, props!

[macipusy]

I LOVE the way it turned out. It has very nice off boost power. Spools up nicely (but I have it rev limited to 5K ATM for break in safety with very low ignition advance....like 10 degrees on E85. I will raise it to 7K redline after 1000 miles.

I am currently working tuning cold starts every morning and drive ability settings during lunch times.

The exhaust sound is more 2.5L ish vs 2.2L ish. I am super happy that I was able to build this up from the ej22t. Best block IMHO.

And with the 4.11 FD, the td06-20g does not feel big at all....very little lag.

And it's slipping the stock clutch at spool up....it's OK for now, since it will keep me out of boost till broken in.