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Old 11-26-2006, 12:01 AM   #76
ten80
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Ok, today was a mixed success.

Timing belt installation was unsuccessful. Installed the belt, realized that it was one tooth off, then remembered that I was also going to do the water pump and thermostat. Both of those were missing gaskets, so back to the dealership I go on monday!

I did have a great success fixing the rear control arm threads that I borked when not paying attention to bolt straghtness. Thanks to a friend at NAPA who tracked down the 14x1.50 tap needed. He also found me the 12x1.25 tap I needed to clean up the mashed ball-joint threads on the front left control arm. It turns out that I didn't need to remove the ball joint anyways. I highly recommend removing the entire front subframe/control arms/drive shafts/sway bar/steering rack assembly instead of removing one piece at a time. DUH!

Wiring guru Matt Monson came over and we started trimming the legacy harness and finding out how to make the gauge cluster and dash harness functional. I'll need to track down the diagnostic manual which has the pinouts for all the connectors in the dash (hvac, radio, cluster, etc). Not a problem since I'm going to the dealership anyways!

xntrk75- after looking at the dash harness, we think it will be a heck of a lot easier to not touch it and use the legacy cluster. We could do this by merging the harness before the SMJ, using pinouts from the diagnostic manual. Are you suggesting that the legacy cluster will have problems with the VSS? I have yet to find out if the VSS is 2 or 3 wire. Also, did you remove any of the ATC wires connecting to the SMJ/tranny plugs, or did you just leave it in, untouched and with the connectors unplugged? it looks like there is only one wire going from the ATC to the ABS ECU and it would be nice if it was the only wire that should be connected to the ATC. The other option is removing the legacy ABS ECU from the ABS controller and installing the WRX one. Since the ABS units look identical and have identical plugs, I suspect that the ECU's can be swapped. I'd love to toss that ATC out the window . Thanks again!

back to my grad school application, wish me luck! Hopefully I'll snap a few pictures of the wiring tomorrow so everyone can see the progress.
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Old 11-26-2006, 11:23 AM   #77
xcntrk75
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If you look at your original legacy harness, at the plug which connects the VSS on the original transmission, you will see if it is the 2-wire or 3-wire.

On my model (a gen earlier then yours and may be completely different) the 2-wire VSS supplies the speed signal to the instrument cluster which contains a micro computer that calculates both speed and odometer. The cluster then presents speed/mileage and outputs the speed signal to the ECU. VSS->Cluster->ECU

On the newer (wrx) models with the 3-wire VSS, the signal produced is supplied to both the cluster and the ECU simultaneously. So the cluster is not performing any processing of the signal prior to ECU as with the 2-wire system.

I was unable to get the 3-wire VSS to work with my original cluster. It would feed and satisfy the ECU just fine, but the signal produced was incorrect for the cluster to process speed & mileage, so I had to revert back to the 2-wire system. This is why I recommended you use the VSS compatible with the cluster (i.e. wrx cluster & wrx VSS).

As for the wiring, the majority of my connections were performed at the ECU area. I ran the new SMJ independent of my original harness all the way up to the engine connectors. It runs in conjunction to my original front-cord. I had to splice over the AC and Alternator cords but otherwise the entire motor is ran off the new harness. The cluster however is managed via the original harness with the exception of the new signals at the ECU (such as temp, fuel, rpm, etc.). The OBD-II was a bit of a pain but does carry over well and I use it every day with realtime ecu logging. The flash connectors are a big pain and I opted not to transition these which in hindsight is a limitation. These are important if you ever want to run a reflash EM whereas I’m now limited to only piggy-back EM since I didn't carry them over. I would suggest transitioning these plugs too.

As for the tranny, I left all the AT system in place (plug wise) and simply disconnected. I too switched from AT -> MT so I had to carrier over all the MT related plugs in the wrx harness such as; clutch switch, neutral position switch, MT starter interlock relay, and VSS if you choose to use wrx.

Hope this helps
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Old 12-06-2006, 10:49 AM   #78
ten80
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xcntrik75, thanks again for the clarification!

ok, quick update from last weekend:

1. changed timing belt, water pump, thermostat, belt tensioner, and spark plugs. A few weeks ago, we also did the clutch and flywheel, plus we're going to change the tranny oil to Redline (3qt 75w90NS and 1qt shockproof) and as usuall, Mobil 1 sythetic is going in. This motor is going to run smoooothly!



2. legacy AT vs WRX MT tranny. I can lift the wrx tranny by myself, it's not too bad. However, the Leg tranny is extremely heavy. I wouldn't be surprised if the car ended up a little lighter or at least the same weight as it was before we add the turbo junk.

PS. Legacy motor is sold and we're glad to see it go

3. Legacy harness on left, WRX on right. If you are considering a swap, take a look at his picture and imagine your self becoming intimately familiar with each and every single wire. Sounds like fun, eh?

Last edited by ten80; 01-22-2007 at 02:28 PM.
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Old 12-06-2006, 11:15 AM   #79
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Holy crap, you guys pulled the entire LGT harness too? Man that's thorough...
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Old 12-06-2006, 03:14 PM   #80
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perhaps too thorough. I now think it might have been nice to leave the legacy dash in as well as the harness. At least it is much easier to locate the wires and follow their paths with the harness out of the car. Oh well, definately no turning back at this point!
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Old 12-08-2006, 12:41 PM   #81
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When's X-mas break start and the fun continues?
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Old 12-08-2006, 02:21 PM   #82
ten80
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Hey Matt congratz on joining the legacy forum

Break begins next thursday at 3pm after the last of 5 grueling finals. I have 33 days off and a lax work schedule
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Old 12-09-2006, 04:11 AM   #83
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Quote:
Originally Posted by ten80 View Post
PS. Legacy motor is sold and we're glad to see it go


so......what did ya get for it?....I did PM you asking about it...Dont know if you missed that or already had a deal pending or what...


My plans changed anyways..but still curious what you got for it?
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Old 12-09-2006, 07:50 AM   #84
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Quote:
Originally Posted by ten80 View Post
Break begins next thursday at 3pm after the last of 5 grueling finals. I have 33 days off and a lax work schedule
Wahoo, this thing will be done and on the road by the end of break then huh?
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Old 12-09-2006, 10:20 AM   #85
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If it isn't I'm seriously going to cry and you guys can make fun of me. I like my 03 TS a lot, but I NEED A BOOST FIX!!!
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Old 12-17-2006, 04:09 PM   #86
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xcntrk,

I just ran into this vss issue. Since we are using literally all the wrx drivetrain so I assume we will need to use the 3/4 wire speed sensor. For some reason there is a fourth wire, brown/yellow that I cant find anywhere in the diagrams on the speed sensor plug. If we use the wrx speed sensor, you are saying we need to use the wrx cluster. Is it possible to swap speed sensors so we can use the lgt gauge cluster? If not, will the wrx gauge cluster plug and play with the LGT connectors (still splicing gauge functions from the wrx ecu) or do I need to retain all of the wrc gauge cluster plugs?

I have also ran into an issue with the cruise control. Did you leave the lgt at cruise control system installed or did you splice in the entire wrx cruise control stuff?

Thank you very much for all of the pointers!

Kevin
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Old 12-17-2006, 07:04 PM   #87
xcntrk75
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Again I’m not certain the differences between my BD model and your BE…

That said, in order for me to get the speed signal working correctly (at the cluster) I had to revert back to my original Legacy speed sensor, pigtail, connector, and wiring. My model had the original 2-wire speed sensor which interfaced directly with the cluster, where the speed was calculated, presented on the gauge, and fed to the ECU.

Originally I wired in the WRX 3-wire (or maybe 4?) sensor, pigtail, connector, and wiring. This architecture does work to supply the ECU a speed signal, but my original Legacy cluster would not read it, nor display the speed, hence the need to switch back.

As for cruise control, I used my entire original system. Had to move and relocate some portions but the entire system is original Legacy and works great!

Hope this helps…

PS: Almost got my LGT back up and running after a long weekend installing my new hybrid motor, big turbo, and fmic…
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Old 12-17-2006, 11:13 PM   #88
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xcntrk75, once again, thank you very much for the insight!

quick update:

Bad news: Wrx is now probably crushed into a million bits. Here it is on the way to the salvage yard. We'll miss is


As you can see, the legacy now has the WRX motor and tranny. there's much wiring and fitting of various components to be done. As you can see, we started the process of replacing kevin's short block.


Well, turns out that kevin's turbo melted a vacuum line that went to the fuel pressure regulator. This caused his car to run lean and detonate in cylinder #4, leading to eventual compression loss and massive oil consumption. Here are some shots of the process:

V2 motor

nasty heads! this is what happens when you leave a block sitting on its side in a shipping yard- nasty, tough rust INSIDE the coolant passages!. Be careful when buying JDM swaps!

Here are the V2 heads


Luckily, kevin has an almost brand-new V8 Ej207 block onto which we plan on installing the v2 heads.

Of course, there was a snafu. A cam guide bolt broke in the head because of a defective torque wrench. Hopefully a machine shop can get this one out.

Kevin did a little more work on the wrx harness and soon I will start putting exhaust and engine bay bits back on the legacy. Hopefully kevin's car will be resurrected this week!

Last edited by ten80; 01-22-2007 at 02:29 PM.
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Old 12-20-2006, 11:05 PM   #89
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xcntrk75,

Both vehicles have the same vss so we should be good to go with the lgt gauge cluster.

Did you use the wrx radiator and fans? Did you use the wrx plugs or did the lgt harness plug and play? Curious because I do not have the lgt harness to look at or the diagrams at the moment and can't compare.

Also curious about exactly what you spliced with regards to the alternator system and a/c. I have the harness torn down and am wondering if these splices were made within the engine bay or back in the cabin? Please say engine bay side with regards to the a/c :0 I have cut out all of the hvac stuff leaving only wires providing i/o from the ecu. Thus within the cabin there are no remaining hvac wires. The alternator looks pretty simple, wires just get spliced before the fusebox?

Thanks again for all of the info! Your help is priceless right now!

Kevin
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Old 12-21-2006, 01:19 AM   #90
ten80
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Update: yesterday was a fairly productive day. The tranny and shifter linkage are completely bolted up and I'm almost done crawling around underneath the car. It's about time, I still am picking grit out of my ears

what is happening here, sparks!?

OOh, sparks!

I don't think that this is a factory option!

We also nearly completed assembling kevin's V2/V8 STi hybrid motor and we installed an enormouse FMIC. We're practically running a chop shop in his garage!





Tomorrow will be interesting. We've had 24" of snow and 12" more a predicted. I may have to snowshoe over to Kevin's to work on the car. No kidding!

Last edited by ten80; 01-22-2007 at 02:30 PM.
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Old 12-21-2006, 06:49 AM   #91
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Looking good…

I used the Legacy radiator which is required (horizontal core) for my generation. Fortunately you’re in luck as the BE’s use a vertical core meaning you can swap between the wrx/sti or even aftermarket koyo radiators. As for fans, I’d think ahead a little here. Obviously you can use either set (Lgt or wrx) but I would stick with the fans which provide the lowest profile (likely the legacy). You never know when you may need to shove a fmic pipe in-between the motor and fan assembly, so the more room available the better. But I believe either would work fine, just carry over the appropriate plugs.

As for alternator, I just spliced the newer wrx style plug onto my old front engine cord which drapes over the motor. This was needed to run the newer wrx style alternator and works great. For AC, I kept my old original AC pump and entire system. The mounting is identical so I simply carried it over to the new platform. There were some fundamental differences in the pump plug and i/o so I found it easier to keep it all original LGT.
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Old 12-21-2006, 10:29 AM   #92
ten80
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Thanks for the info. We'll proabably use the WRX radiator then, since the LGT one has a nipple for tranny cooler hose. We have about 8" between the radiator and the motor- it seems that the BE's have a cavernous engine bay.

The AC system is very different in the legacy. The connection ports in the firewall resemble those on Kevin's GC impreza and not our WRX. I think we'll be keeping most of the legacy AC bits but we might have to get creative with the hose routing and/or have some hoses made.

Now I must shovel my driveway in the hope that the city can remove the 30" of snow in my street today.
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Old 12-21-2006, 11:44 AM   #93
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damn... I'm glad its gonna be rain when it gets here

Looks like you are making great progress on the swap. Can't wait to see it finished.
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Old 12-21-2006, 01:23 PM   #94
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Now I must shovel my driveway in the hope that the city can remove the 30" of snow in my street today.

I hate you!



My brother and friend just left for Brek and FT Collins yesterday.....I turned down the trip to better fund my swap........
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Old 12-26-2006, 01:10 PM   #95
ten80
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quick update:

wrx ECU harness is prepped and the legacy engine harness is almost finished. It's amost time to put the harnesses in and turn the key!
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Old 12-26-2006, 02:38 PM   #96
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Cooooool!

Had to use both harness eh?
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Old 12-26-2006, 02:57 PM   #97
ten80
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yep. The legacy interior harness is necessary to control the dash, doors, AC, etc. Additionally, we're using much of the legacy harness to control engine bay functions not associated with the WRX ECU. The WRX engine harness will be used to control the motor and other functions tied to the ECU. We think we found a way to override the "neutral lock" feature of the AT legacy harness by wiring it into the MT clutch pedal switch. Additionally, the legacy engine bay harness plugs into the wrx ABS computer which we bolted to the legacy ABS unit. This means that the AT TCU which normally has an input to the ABS unit and AT tranny will not be needed (theoretically, at least).

Looks like we're down to about 12" of snow here, it's been quite warm. All the better for working in the garage!
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Old 01-03-2007, 10:53 AM   #98
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I haven't gotten any phone calls in a few days. I take this as a good sign? Update please...
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Old 01-03-2007, 12:53 PM   #99
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Update....Update....Update....
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Old 01-03-2007, 01:27 PM   #100
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Update....Update....Update....
12345
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