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Old 04-04-2006, 06:51 PM   #1
SOLUTION
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Default Fitting an '05 Intake Manifold onto an '00 RS

I recently aquired an '05 intake manifold with the fuel rails and injectors and I will be modifiying it to fit on my '00 RS. With that in mind, this thread will be a source of info for others wanting to do the same and hopefully some people here can help with questions I might have. Here is a quote from Steve Sulatycki someone posted on the rs25 forums on what needs to be changed:

"For 00 -> 05, you'll need to change:

- Coilpack and spark plug wires
- Fuel rail (all components)
- Fuel injectors - they are now "WRX" style and stock WRX units work well
- Drill holes for the '00 TB - bolt pattern is different
- Drill a hole/boss to mount in the MAP/IAC sensor onto the manifold. The
05+ are MAF based and as such there is nowhere to bolt the MAP onto.
- Port match the intake runners to the '00 intake ports. The ID of the
runners on the 05+ manifold are larger and the misalignment that results
has to be dealt with
- Relocate/mount the throttle cable to the manifold. All 05+ are
electronic TBs and there no existing mount for the throttle cable."



Here are a couple pictures of the manifold I have that I'll be working on:



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Old 04-04-2006, 06:56 PM   #2
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I also just purchased a throttle body I can use when designing the adapter plate between the TB and manifold.
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Old 04-04-2006, 09:29 PM   #3
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Here are some pictures I took of the ports on the intake manifold versus the ports on my heads with the intake manifold gasket overlayed so you can get an idea of the difference.


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Old 04-05-2006, 01:41 AM   #4
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For clarification:

Is the intake manifold GASKET from the 05 manifold or the 00 manifold?
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Old 04-05-2006, 09:40 AM   #5
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The gasket is from the '00 manifold.
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Old 04-05-2006, 10:14 AM   #6
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Thanks for putting this up...i will be followign closely for obvious reasons...

i have a set of spare '05 heads lying around... i'm tempted to swap my cams and springs over to those for ease.... instead of dealing with the port-matching. unfortunately, I don't have the tools for the spring swap... I should probably cool into that
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Old 04-05-2006, 10:18 AM   #7
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oh, also...my manifold came with all the wiring and sensors and such....think i can just reuse the 05 coil pack and fuel lines/injectors? or will there be miscommunication with my '02 ecu?
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Old 04-05-2006, 10:55 AM   #8
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Quote:
Originally Posted by staticfritz
oh, also...my manifold came with all the wiring and sensors and such....think i can just reuse the 05 coil pack and fuel lines/injectors? or will there be miscommunication with my '02 ecu?
I'm guessing that is fine.
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Old 04-05-2006, 10:46 AM   #9
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Quote:
Originally Posted by staticfritz
i have a set of spare '05 heads lying around... i'm tempted to swap my cams and springs over to those for ease.... instead of dealing with the port-matching.
I wouldn't be surprised if the '05 heads are no better than your older heads. Manufacturers (from what I've seen) generally aren't too worried about optimum port matching.

I'm starting to think I might look into having tabs welded onto the flanges to allow mounting an '05 intake on my older Phase I DOHC heads. I wouldn't think it would be all that hard for a machine shop to do. Hmmmm....

Pat Olsen
'97 Legacy 2.5GT sedan
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Old 04-05-2006, 10:58 AM   #10
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Quote:
Originally Posted by Patrick Olsen
I wouldn't be surprised if the '05 heads are no better than your older heads. Manufacturers (from what I've seen) generally aren't too worried about optimum port matching.

Pat Olsen
'97 Legacy 2.5GT sedan
Yeah, part of the reason I took the pictures of the ports was to see how off mine were. I'll probably just leave the ports on the heads alone since I don't want to mess up the great port job that was already done. I'd love to see pictures of the ports on an '05 head.
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Old 04-05-2006, 09:56 PM   #11
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Here is a shot of the '05 manifold. On the floor to the left is the IAC and on the right, next to it, is the IAC from an '00. Circled in the picture is where the IAC mounts - it has one passage that leads to the pipe I drew an arrow to and the other leads to the penile looking thing to the left of the mounting location. I'm guessing the piece on the left must lead to the intake to allow air in when the IAC opens up.

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Old 04-05-2006, 10:15 PM   #12
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what does the IAC mounting look like on your '00 manifold?
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Old 04-05-2006, 11:24 PM   #13
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Quote:
Originally Posted by SOLUTION
Here is a shot of the '05 manifold. On the floor to the left is the IAC and on the right, next to it, is the IAC from an '00. Circled in the picture is where the IAC mounts - it has one passage that leads to the pipe I drew an arrow to and the other leads to the penile looking thing to the left of the mounting location.
That looks more like the EGR port to me, particularly when you say that it looks sooty. I have two intakes sitting in my garage - an EJ25D and an EJ20G - and on both of those the IAC port is just a circular opening. Just took some pics now....
EJ25D:


...and EJ20G:


The EJ25D's EGR port looks like so...

Obviously not exactly the same as your '05 intake, but note the split port and also the port below where the EGR attaches (it's not penile on the EJ25D intake , but it otherwise looks the same). You can kind of see in the picture on the bottom of the intake the same sort of passage snaking along the bottom towards the center of the intake.

Based on some PMs I've bounced back and forth with Jay Storm, there are some older Subies that had the IAC integrated into the throttle body. Perhaps with the throttle-by-wire the '05+ cars are able to control the idle with the throttle body?

Pat Olsen
'97 Legacy 2.5GT sedan

Last edited by Patrick Olsen; 04-05-2006 at 11:41 PM.
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Old 04-05-2006, 10:27 PM   #14
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oh...that penile thing has a pipe that attaches to the head under it...i think it's an oil passage....if not, then coolant.
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Old 04-05-2006, 10:30 PM   #15
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Quote:
Originally Posted by staticfritz
oh...that penile thing has a pipe that attaches to the head under it...i think it's an oil passage....if not, then coolant.

Definitely not coolant. Maybe a breather line? That would explain the sooty build up. I was just assuming the piece that mounts there is an IAC. If it was a breather line I would think it would have one for the passenger side too.
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Old 04-05-2006, 10:33 PM   #16
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Maybe some sort of electronic pollution control valve?
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Old 04-06-2006, 10:26 AM   #17
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Yeah, I had wondered that - It makes sense that the electronic TB could control idle too. On my '00 RS the IAC is integrated into the TB.

You can see it here:
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Old 04-09-2006, 03:58 PM   #18
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Here is a picture of where the MAP sensor is on my '00 manifold (right under the spark plug wires). I need to figure out where to mount it on my '05 manifold.

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Old 04-09-2006, 06:14 PM   #19
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Here is a shot of the '00 manifold where the MAP sensor bolts into it with measurements for the size of the hole and the distance between the two bolt holes (center to center):



And one shot of just the money side of the MAP sensor:

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Old 04-09-2006, 06:25 PM   #20
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There is a nice flat area on the top of the plenum on the '05 manifold where I think it could be machined flat and the holes added for the MAP sensor. I wonder where TWE put theirs? Here is a picture of the TWE job - I can't tell where they put it from the picture.

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Old 04-09-2006, 08:47 PM   #21
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Quote:
Originally Posted by SOLUTION
There is a nice flat area on the top of the plenum on the '05 manifold where I think it could be machined flat and the holes added for the MAP sensor.[/IMG]
I haven't held one of these intakes in my hands, but from the pics you've posted, it does appear that the top of the plenum is about your only option.

Pat
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Old 04-09-2006, 09:00 PM   #22
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Quote:
Originally Posted by Patrick Olsen
I haven't held one of these intakes in my hands, but from the pics you've posted, it does appear that the top of the plenum is about your only option.

Pat
There's also room on the side of the plenum that the throttle body mounts to, but I'd have to investigate how much the TB would be in the way. The top is surely easier to have machined. Seems like a good spot.
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Old 04-09-2006, 08:07 PM   #23
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are you sure twe used a map and not a maf?
could that be it integrated into the throttle body?
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Old 04-09-2006, 08:49 PM   #24
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another option is to utilize the tube that the '05 ran through
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Old 04-09-2006, 09:02 PM   #25
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Quote:
Originally Posted by staticfritz
another option is to utilize the tube that the '05 ran through

What do you mean?
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