DrinkItDown's 1996 Subaru Impreza GM6 EJ22T/EJ25 hybrid

[DrinkItDown]

Hey all, I will begin copypasta-ing my project here, from posts on other forums. Forgive me if a few things mention members of forums that are not here, I don't really have the time to go through post by post and edit stuff out.

Please note, this project originally started out as a pretty run of the mill EJ22T swap.

For more information outside of these posts, you can always hit up my youtube channel, or follow me on twitter.

http://www.twitter.com/MegamanEXE
http://www.youtube.com/MegamanEXEv2

Enjoy!

[DrinkItDown]

.:Originally Posted on 10/12/09 on Columbus Racing:.

MR2 is going bye bye, and I am picking up an EJ22T shortblock on Saturday from someone on RS25.com . Don't plan on doing anything super special with it, just something to have fun with rallycrossing and playing in the snow. The motor that is in it has a bunch of issues, and I am pretty sure the block is cracked. Probably won't see an autocross, as the transmission is too fragile for it. If it did, I would be babying it for sure.

Anyway, short parts list:

EJ22T bottom end
EJ22E Heads/Cam/Intake
Not sure what to do about an Intercooler, I hear there are clearance issues with a WRX one, maybe a stock EJ22 one.
WRX Injectors
WRX exhaust bits
WRX crossmember
TD04 Turbo, maybe a VF39, but I kind of want to avoid lag as much as possible.
Megasquirt II
Walboro 255 lph

and I'm changing out the tranny for a new one.

[DrinkItDown]

I picked up the shortblock yesterday. He included some "bonus parts" I guess you would call them.

[DrinkItDown]

Got the engine on the stand today, and inspected the cylinder walls a bit. Look super clean, and still had the cross hatching on the walls. Pistons looked great also, except for a small mark where it looks like a valve met one, but I don't think thats a problem.

[DrinkItDown]

Yes, I have the heads from Bill. One of the rocker arms is busted on one, but the rest of the heads look ok. They are going to get inspected regardless, but at the very least that one arm needs replaced. So if anyone has the hookup on those or has one laying around, let me know. I will take some pics here soon, I am currently in a THRILLING "Technology, Society, and Culture" class.

Here are the pictures of the heads I got from Bill. As you can see, one of the rocker arms is busted, but Subaru designed them to be individually serviced, so I should be able to fix it.





Hopefully it won't be long before I start assembling everything, but I may be between jobs soon so that could slow things down, even for a budget project like this.

[DrinkItDown]

Ok, ECU is here. I got a killer deal on this. Paid $120 plus shipping. He included two GM sensors, coolant temp and something else, IDK, I am probably not going to use them.

I was kind of hoping it was a PCB V 3.0 or higher, but its a 2.2. Thats fine, I will just have to be more careful with my wiring. This is a Megasquirt I, on a PCB version 2.2. It was installed on a DSM, so I may need to take out the jumpers and such for that setup, but thats no big deal. I may upgrade the processor to a Megasquirt II, I don't know yet. Not quite to that point to worry about it, but here are some pictures.

[DrinkItDown]

Project is in a short stall, because I decided to build a new Core i7 920 computer, to replace my old Core 2 Duo E4300 machine. I am trying to find someone to take care of the rust on the car, and have been chatting with Kevin Clifford on Columbus Racing. I also want to do a full interior swap, as mine is kind of ratty. The zip tie is from the previous owner, I didn't do it.

[DrinkItDown]

Got heads! They came off of Nathan's car. This will let me run factory dual port exhaust components, which is awesome, because we thought we were going to have to use the F word (fabricate). I do need to get a WRX crossmember to make all that plumbing work, though. I will be running them with EJ22T head gaskets, which will give me a fairly low compression ratio, but I'll live. I am also going to be running a TD04 for nice quick boost, and should be picking that up here from someone soon too.

Tristan on CR has been helping me sort out the cluster**** that is trying to get Megasquirt running on a vehicle that it hasn't been installed very much on, and I am very grateful for him taking the time to answer my questions. You rock man! There is a rumor that they have decoded the factory crank trigger wheel, which would mean I won't have to graft an EDIS in or anything, which is good. I should also be picking up the MS2 processor board from him soon, too. Just have to get a moment to do it.

Still trying to find a shop in Columbus to fix the rust for a reasonable price. I don't need paint matched or anything, I just need the rust fixed and primered over for now. If you know anyone, please tell me.

Here are some shots of the heads ratchet strapped to the block for pictures:





The Intake manifold and crank trigger wheel are donated parts from ZB, thanks man! So awesome of you to do that for a guy you met 5 minutes ago. LOL

Picking up more need parts from Byers today, like the head bolts and timing belt.

[DrinkItDown]

No timing belt yet. I forgot about a few pulleys, but its coming soon enough. I am going to start working on the intake manifold in the meantime. I need to see about swapping the side-feed injectors and fuel rail over to the 2.5 intake manifold I have, which has top-feed injectors and fuel rail. I am also going to clean and reorganize my currently messy garage.

[DrinkItDown]

[DrinkItDown]

Timing kit arrived yesterday, 3 days late, but its here now. Way too expensive for 4 pulleys.

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Car had near catastrophic overheating yesterday. Car is officially parked to being the swap. Picking up a new DD this weekend, a mint condition VW Quantum.

[DrinkItDown]

http://www.youtube.com/watch?v=N1Umkj_dSRQ

[DrinkItDown]

My Canadian relatives were in town this weekend, so I only had about an hour to do any work on it. I took the hood off, airbox and pipe out, AC disconnected (already evacuated by Sean/crossle), took the radiator out, took the battery out, disconnected the alternator, and thats about all I had time for. The rest of the weekend was spent hearing "eh" a lot.

[DrinkItDown]

Started today with a much needed upgrade to the garage lighting.


We then proceeded to finish disconnecting whatever was connected to the motor in it, and began to take it out.

[DrinkItDown]

Where the old motor will rest while we take the stuff of it to transfer to the new motor.


As you can see by how wet the inside of the transmission is, the rear main seal was leaking pretty badly. I didn't take any pictures of the flywheel or pressure plate, but they are pretty burned up.

[DrinkItDown]

This was a massive PITA, and I broke a few pins on the bottom row, but I think it will be ok to use. Pretty sure I can fix whats broken.

[DrinkItDown]

Got the timing belt and most of the accessories on the motor. Left the alternator off to make hooking up the oil pressure sensor easier. Trying to figure out what to do with the timing covers, may need to fab something up. Also took one head off of the old motor to see if we could see any damage.

[DrinkItDown]

Not planning on stripping the interior out, but want to remove some weight from the car. What I will probably do is carpet over what I took out, in order to dampen the sound a bit.



And I found a random copy of Pokemon Red under the carpet in the trunk.

[DrinkItDown]

Ordered some parts, and I am waiting on them to get here. The first is a 1991 Legacy Turbo engine crossmember, one of the parts I was having a pretty hard time finding.


The second is a 2005 STi Intake manifold, with TGV's and fuel rails to match. Throttle body not included, which doesn't matter cause I can't use a stock STi one anyway.

[DrinkItDown]

In my never ending quest to not waste my weekends, after the Porsche club autocross today I focused on the gas tank of the car. It was full of 87 when I parked it. Heres the list of ingredients to remove it:

1x long section of Audi 4000 heater hose
1x Fuel pump
1x Jumper cables
1x Battery
1x Fuel Jug
1x Fire Extinguisher....just in case

I didn't take any pictures of my setup to get this done, but because I know you need something to look at, here is the Fuel jug filled with old gas.



While I was in there, I took my Walboro 255 that I had laying around from my Turbo Mustang days (never used it) and adapted it to work in my Subaru. Didn't take any pictures of that setup either, although I should have. Heres a picture of the stock one to, again, give you something to look at.

[DrinkItDown]

Megasquirt shipped today, should be here by Wednesday.

As far as the Turbo Crossmember goes, I am awfully close to filing a Paypal dispute, as its been almost 2 weeks and the crossmember hasn't shipped yet.

But the good news is, THE MANIFOLD IS HERE! Pictures of the TGV's, Manifold itself, and the STi fuel rails that are on em. Now looking for someone that will gut my TGV's for cheap locally.

[DrinkItDown]

MS came in today, so now I can start working on the harness adapter.

Megasquirt II v3.57 PCB

[DrinkItDown]

My turbo crossmember got routed to the wrong UPS facility, some place down near Cinci. The new scheduled delivery date is 9/20, and I've lost another weekend for a stupid reason.

[Legacy777]

I edited your posts to keep the pictures more linear so you don't have to scroll out to see them.

Please try and post future pictures similarly.

Thanks