SKIP TO THE BOTTOM (#18). This post is old, just didn't want to create a new one.



Ok, for starters, i've been working on a swap for my car for a very long time, it was totaled about 6 months ago, and I am still working on it =( Between two jobs/national guard and other things, I don't have a lot of time.
I've been reading this board daily since the crash, and I cannot find some of the answers I am looking for. I know most of the MAJOR components needed for the swap, and I have most of them. I want to know about any parts I might overlook.

It's a 2001 2.5rs.

My car took a tree to the front end, so basically everything from the firewall forward has been or is pending replacement.
I have a 2004 wrx engine. I have the ECU/wiring harness. I have the harness from the old engine. I have the complete books/wiring diagrams for both engines. Turboback exhaust, wrx cross member.
The RS tranny did not get damaged, will be using that.
Still need a radiator and cooling fans, not to sure what to get there.
I'll need a clutch, but have not purchased one.
Little stuff like gauge pods, fuel pump, Bov, ect. The rpm/mph gauges from the RS will obviously be obsolete.

What other odds and ends will I need to complete this swap? I wont be doing it myself, but I don't want to have it sitting in my mechanics garage for a year waiting on parts here and there. I've read every sticky and every post about completed EJ20t swaps and still am not sure if I am missing anything.

Anything?

Well, it be best of you listed exactly what you have.. I could suggest stuff like PS pump system, FMU, boost solenoid, MAF setup, and you will custom fabbing stuff like rad hoses ect.

Also I would suggest to anyone to replace stuff like F & R main seals, h20 pump, oil pump, thermostat, while the engine is out. Even if its only a year old. At least you know they will work/ are new. Also new engine mounts, and steering rack bushings.

Randy

bump :)

The list of things you need is huge and even if you have it all there will be some stupid thing that you will need that will hang you up.

List for my swap:
03 WRX engine/turbo/STi IC/UP/ECU
Turbo Legacy x-member
bulkhead harness from WRX and the car it's going into
New flywheel/clutch (if you keep the N/A trans you have to get a RS clutch/flywheel WRX one is the oppistie and won't work)
engine and trans mounts
Turbo back exhuast
PS pump/lines and tank from WRX (you can use the RS lines with a little careful bending)
AC from the RS (if you're puting it back in)
Lots of help from friends and a lot of time spent wiring
Beer to pay the friends :)

I know I'm missing a few things. I started with a 96L so anyting I could replace I did. The L rad is working so far but a WRX one won't bolt in without modification. The L trans won't last long (mine ate 2 in 6 months untill I put a RS one in. So far it's holding)
If you plan on doing intake/injectors/UP/most motor work do it while the motor is out of the car. Replacing the seals/pump/timing belt is a good idea but depending on the history and condition of the motor it may not be nessary.

The existing gauges should work but I put in a v3 STi cluster while I had the dash apart so I'm not a 100% sure. Other gauges EGT/Boost/oil temp/oil pressure/ect need to find a home but it's easy to make places to fit them.

Take you time, make sure everything is the way you want it. Otherwise you will be kicking yourself later when you have to tear it apart again to fix it.

Thanks everyone for the imput. A few questions:

what is this?
"PS pump/lines and tank from WRX " Assuming gas tank/lines?
"F & R main seals"
I did not know about the flywheel and clutch, I am sure that would have been an issue! I am more than likely killing the AC, so not worried about that. I live in Maine, no need for AC!
Keep the info coming, I am hoping to have this swap done and on the road in another month or so. Pending all the damn paperwork the state is going to make me do of course.

Also my Engine has 4500 miles on it, no worried about replacing much. I don't plan on upgrading the power much either, because I don't want to buy a new tranny.

Thanks again.

The seals they are talking about are the crank oil seal (front) and the rear main oil seal. The large seal for the crank in the back of the block.

The power steering lines (P/S lines)

i'll be starting my swap later this week. I just ordered my clutch and fuel pump today.. everything else is a go.. minus a few misc parts..

As for the clutch.. If your using the 2.5rs tranny, then get a clutch for a 2.5rs. If your using a wrx tranny, then get a wrx clutch.. They operate differently and won't interchange.

^^ but also use the 2.5 RS flywheel, and starter... and vise versa.
or so I've heard. Whatever flywheel you use, use the corresponding starter. That just makes sense.

Randy

do you use the factory 2.5 rs mass air flow sensor or do you have to get a wrx one? also, do you guys know of any good places to get parts from online?

I had to use a WRX one but I had a 2.2L rather than a RS so I don't know for sure.

www.subaruwrxparts.com
www.subaruparts.com

get the 02 wrx one- the 98/99 MAFs are different

How about my radiator?
I don't have any radiator at all, so what should I buy for the swap? the 2004 WRX radiator, an RS radiator, or some aftermarket radiator?
if they'll all work, which one requires the least amount of mods to fit?

How about my radiator?
I don't have any radiator at all, so what should I buy for the swap? the 2004 WRX radiator, an RS radiator, or some aftermarket radiator?
if they'll all work, which one requires the least amount of mods to fit?

stock RS: it will work, bu there have been peopel who have had problems with over heating at the track and stuff

Koyo GC8: i have this one, it fits into all teh stock mounts, but i had to swap the upper mounts with a 99 RS because the 98 mounts are different. the radiator fits perfectly, but the upper hose needs to be trimmed and u need low profile fans(i have flex a lite fans)

stock WRX: they will fit in the lower mounts, but the upper ones will need custom brackets made up, the subaru fans should fit fine, the upper hose should have decent clearence

Koyo GDA: this will fit, BUT there will be loads of issues, not only will teh fans be very close even with FAL fans, but the upper radiator hose could start to rub on the altinator pully.

legacy turbo into 98RS: this should be a drop in, i have yet to see it done, but after having looked at both radiators i am 75% sure that it will bolt on no problem.

when choosing the radiator you have to remember that the upper hose on teh GD cars is in the center and i have a feeling that the support on the GC bodys are closer than the GDs

Another note:
on the GC radiators they are missing one of the coolant line nipples, what i did was run teh over flow from the uppper tank directly to the over flow, the extra coolant feed i sent to the radiator and hooked up where the over flow is normally hooked up on a radiator. then i used a 93-95 Mazda RX7 radiator cap http://forums.nasioc.com/forums/showthread.php?t=639243&highlight=rx7 post # 16

if you go to mazda its the cap for the RX7 thats on the motor by the water pump
PN:
KF01-15-205 Cap,Radiat

You can also use a C&R radiator, but it's about 200 more than the Koyo rad. You might be able to find a fluidyne rad to fit as well not sure though.

the rs radiator will do good- Its been 3 years now sinced I dropped in a wrx in my 2k rs.I drove it everyday from and to work everyday- traffic in Honolulu is the worst- no problem on overheating. Occasional scca-no overheating probs. as long as you use the wrx's four-speed rad fan. You can certainly use the
ip cluster from your rs- just follow your wiring diagram.
r u in the guard? so when you guys are going to relieve us here in iraq? :devil:
good luck buddy

just put in the stock 2.5 radiator today, like said above, just going to run the overflow line directly to the overflow tank, and the other hose going to the nipple coming off the neck of the radiator. I modded the stock radiator cap and removed the rubber seal, to allow coolant to run through that hose back to the coolant tank.

Looks like RS radiator with the WRX fans is the way to go. I'll see where I can get one. Thanks for the info.

And to sub-sonic:
Yes I am in the guard, and hopefully we wont be BACK over there anytime soon. My unit hit country april 17th of '03 and we left on the april 15 of '04.
Trucking company so we spent most of our time in Kuwait (Navistar, Arifjan, ect), but still the same hot ass desert =(.

I hope for your safe return. I know posting about your car over there is not NEAR as much fun as driving it here, I went through that!

i'm using the rs fans as well. they fit fine.

Koyo GC8: i have this one, it fits into all teh stock mounts, but i had to swap the upper mounts with a 99 RS because the 98 mounts are different. the radiator fits perfectly, but the upper hose needs to be trimmed and u need low profile fans(i have flex a lite fans)


Ok STILL looking for a radiator, I dropped my car off at a shop a few months ago, and I thought they were going to get the rad, simple misunderstanding. So I still need one.

Where did you or anyone else get their Koyo GC8 radiator and flex a lite fans? I'd like to just order them both from one place. I have found a few sites but they want to know the engine code and model code of both cars, and when I sent it they argue that my 2004WRX engine is a ej20T not an ej205 (like the manual says). I just want a radiator that will fit in the mounts and has the extra cooling.

Also I assume I still need wrx P/S lines, pump and tank. I don't know why I need these, as my RS already has them all. Different location?

koyo is sexy. kinda want one for the bling factor, but my OEM is working just fine. what kinda loot have you guys skored koyo's for?

http://www.absoluteradiator.com/ProductPage.asp?idProd=57

These are the ones I am looking at. This is the place that wants to argue about my 04 wrx engine being a ej20t.

Koyo is actually the cheapest one.

Don't waste your breath. I used to correct people for saying Ej20t all day long. All I did was get out of breath. It has come into common usage to mean any turbo Ej20. Just let them call it what they want and order the radiator.

So will this radiator work? I need to order this now, one of the few things slowing down my swap but don't want the wrong thing.
http://www.absoluteradiator.com/Pro...e.asp?idProd=57
First one, the koyo.


BUMPED

i dont even know if a koyo would fit in my car...

the swap sits so close to the front, it almost looks like a thicker radiator will hit the header at the bottom....

anyone have any clearence issues otherwise?

or just be sure to use the slim fans? in anycase, pusher or pullers?

i think you'll hit the NA plastic fans (or it lookedlike it to me). the FAL fans are the bomb. (suck all the juice outa your battery :P)