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Old 12-02-2001, 01:57 PM   #1
EddyRS
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Default RS to WRX Conversion Project (Update)

Well since I'm looking to be the first to do the swap of a 2002 USDM WRX engine into my Y2K 2.5RS, I might as well start up this thread and post the progress of this project.

Sorry I do not have a Digital Camera, but will be using a Regular one to Record the Conversion.

Update #1. (GETTING ALL THE CRAP)

As all of you know I just purchased a 2002 WRX Engine from Subaru/Suzuki of Rancho Cordova. The doner car was a Red-Sadona Sedan (5-Spd Manual) It only had 873-miles on the odometer. The car took front/driver side damage, which took out the entire Driver-side Front wheel assembly, but did little/no damage to the engine compartment. The only thing it did do was smash the battery (Which slattered the side of the Engine) Once I get the engine later this week, I will be cleaning all that crap off, but it shouldn't be too bad. In the crash the only damage to the engine, if you can call it damage, was the Timing belt Plastic Cover, and only the one side, the Timing belt and pulleys were left untouched. (Infact the engine is still timed spot on.) I will have new covers when I get the engine.

So far I have all the associated hardware for the swap. The list follows:

1. Complete Exhaust - To include Muffler. (It looks like I may have a custom 3" exhaust made from the Rear CAT Back).

2. Full Intake - ( I may leave out the "Box" in the fender, and just run a Hose into the fender well, and modify the small opening in the bumper so that I can feed the engine from outside air).

3. Wiring Harness - COMPLETE. (What a MESS!, Now I can see how this will be the hardest part of the Conversion. It looks kind of like a Robotic Octopus, or Spegetti. Man I didn't know there was THAT much wires under the dash....shesh! I may need some help from those who have done a JDM conversion to get this done. But to be truthful, it's not so bad, Luckily I purhcased much of the manuals for both cars (That was expensive) and have the wiring diagrams for the 2002. I think I can use much of the harness from the RS, and connect to the WRX harness. That way I don't have to run all the wires throughout the car (and remove the perfectly good RS wiring that was installed in the factory).

4. Radiator - Had to buy that one......there goes another $325.00.

5. Cruise Control - ( Got that too.....it's a much small unit, and is electonic controlled, not vacum like the RS. Plus it will sit out of the way. Only Prob. It appears that it sits where a part of the RS AC-system sits. Solution: (I will use all AC piping and hardware from the WRX.))

6. Steering Rack & Turbo Cross-Member - (Got both of these, but both are slightly in need of repair. When the wreck happened, and the Wheel assembly was RIPPED from the car, it tweaked the Crossmember mount (just the back one) and bent the driver side control arm of the steering rack. I'm looking into seeing if the C/M can be repaired, and if I can use the control arms from the RS S/R to replace the ones on the WRX unit. (Kind of like the idea of having 3:0 Lock-to-Lock Steering )).

7. Intercooler - (That came out without a scratch. Got the Hood-Scoop apron too, will see if it will bolt up to the RS hood).

8. Misc. Hoses and brackets - (I basically cleaned out the engine bay of the car.

Now I'm just waiting for the Engine....couldn't get it yesturday, as I didn't have a truch to pick it up, and I want to wait until all repair parts are in and let them do the install (I have much to do myself). I will have the engine by end of week, and will be spending some time cleaning it up, maybe do some painting and dress-up while I have the engine out of the car.

By the way......I may be selling my JUN Flywheel for the 2.5RS, as it will not work with the WRX engine. But at least I can keep the ACT clutch.

That's all for now, I'll post later when I start the tear down of the RS.

Cheers

EddyL.
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Old 12-02-2001, 03:11 PM   #2
joltdudeuc
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sweet!

are you gonna take the "2.5 RS" and "SUBARU" off and put "W R X" across the back the 'old' ones in japan and UK?

or are you gonna keep that car a sleeper/rice eater!?

-Gagan
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Old 12-02-2001, 04:12 PM   #3
SONofSAM
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Default Plan to sell!

Any thought! How much your whole RS Engine , tranny , and harness will worth!
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Old 12-02-2001, 07:33 PM   #4
EddyRS
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I have already removed the SUBARU emblems off the back of the trunk, but still have the 2.5RS one. I am thinking of putting the WRX emblem from the 2002 on it. (I don't think anyone will mind as I will be driving in essence a GC8 WRX (hence the change on my profile). I like the emblem better than the Decal. Plus the 2002WRX decal is low key.

I still have a LONG way to go to get this running right....but I have the time.

As for the Engine/Tranny....ect. I am keeping all for now, (as a back up just in case).....Also I want to use the RS tranny with the WRX.

Cheers

EddyL.
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Old 12-02-2001, 09:04 PM   #5
local420
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Talking Sleeper alert!!!!!!!!!!

I would say keep the RS badges!!!! Why should anybody else be the wiser Eddie?



Few other things... do NOT put the stock WRX exhaust on it... Save yourself from Disappointment! Half of the turbo flange on the exhaust is blocked off, and it will make a Tremendous difference right off the bat. Go with a full 3" system.
Good idea about the intake, but it will get noisy!
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Old 12-02-2001, 11:20 PM   #6
EddyRS
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I wish I could get a Turbo-back System, the stock Down-pipe is such a joke. Whats with the area where the by-pass gasses go is blocked.

Unfortunately I don't have any more money. (Well I do, but my wife has taken all access away from me ) I guess I was lucky to get the engine in the first place, So I will have to wait for a little while before getting better parts. Give me a year at the latest.

Cheers

EddyL.
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Old 12-03-2001, 01:59 AM   #7
BongMan
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Thumbs up

good work man! I'm thinking of going this direction as well, maybe in a year though.

you should use the newer wrx badge. I'm planing to use the GC8 style one's. So don't. thanks.

But definately good work. If you need some help i'll definately lend a hand. not much i can do though. i've only worked with bolt on stuff. PM me, i'd like to see your set up when you get underway.
larry
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Old 12-03-2001, 02:08 AM   #8
The Real Oaf
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EddyRS:

Hey, I hate to harsh your mellow, but someone in Newcastle has already done this swap. I don't know the person, but Steve Barsoti(sp) is the indy Subaru mechanic doing the work.

The donor car was pretty wasted, not having a straight panel on it. The recepient car is a white 94(?) Impreza wagon and has all the running gear, exhaust, wiring, etc. from the WRX.

If you need a hand getting the motor, let me know. I have a small trailer and don't mind lending a hand.

Paul
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Old 12-03-2001, 10:33 PM   #9
EddyRS
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To be honest I am not upset that someone else beat me to putting a WRX in a older body.........being the first is not always the best. Frankly I really do not interested in being the first. But it was looking like I was, as no one posted at doing this mod yet, so I figured I was the guinee-pig.

I am just happy that I got a engine for a decent price....one with very few miles and that there are those out there, who are willing to help me in this project.

To all those who have offered to help.....THANKS. I will gladly take any help....even if it is a extra set of hands. You are all welcome to come by and help, or even just to chat. PM me if you want to stop by, and I'll pass on my address.

Again, thanks for the interest.....and see you around.

Cheers

EddyL.
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Old 12-03-2001, 11:32 PM   #10
Chocobo
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Quote:
I am just happy that I got a engine for a decent price....
Just wondering, how much did you pay for the engine?


-Paul
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Old 12-04-2001, 12:16 AM   #11
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eddy

do not forget the rear end gear that matches the tranny gear. More power to you man.

Gino

Last edited by ginowrx; 12-04-2001 at 11:17 PM.
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Old 12-04-2001, 01:03 AM   #12
JZ oo7
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Question

Quote:
Also I want to use the RS tranny with the WRX.
you sure you wanna do that? you know our tranny SUCKS! but anyways, is it a direct bolt on? i wouldn't be surprise beucase IIRC Ed from iSR said that most subaru motors will direct bolt to most subaru tranny. oh, and when you are ready to let go of the flywheel let me know how much...i might be interested, and by the way, where is lincoln city?

jansen
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Old 12-04-2001, 01:07 AM   #13
The Real Oaf
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Eddy,

Again, I didn't mean to bust yer bollocks.

If you need any welding done on the cross member, I can do it at work for Free!

Did you get all the smog related items...like the huge charcoal canister in the rear end? Make sure you have all the slow-down parts so the referee won't nut up.
:monkey:

Paul
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Old 12-04-2001, 02:14 AM   #14
EddyRS
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Dont' worry Paul........I take no offense what-so-ever. If someone else is able to do this mod too....GREAT.....the more the merrier. At least then our older and bolder GC8 bodies will (at least some of them) have the power to go with the looks ......No offense to those with the new body style, but I like the aggressive look of the 99-00 RS's......personal choice....thou I am getting to like the look of the new sedan...if you get the headlight mod, and a Ver5-style wing on it.......but I digress.....

I may call you on that welding....as I am getting the WRX crossmember and it may need to be rewelded at one joint.

As for the smog......I recieved everything for the car. I won't need the charcoal canister as I already have it on my Y2K vehicle. I basically took EVERYTHING out of the engine bay of the donor car....there is nothing left except the Power Steering lines (and I have that on my car).

Cheerio

EddyL.
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Old 12-04-2001, 02:34 AM   #15
EddyRS
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I may have a issue with the capatibility of the RS Clutch and the WRX flywheel.....I will try and find out tomorrow.

God I hope I don't have to get the tranny too.....If I do, I will get a STi unit from japan......it should be cheaper than $2000 that is what the WRX unit is going for.

Shesh......

Well I got the engine.......I'll go from there....right.

Cheers

EddyL.
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Old 12-04-2001, 04:49 PM   #16
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Keep us posted Eddy2.0RS !!!!
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Old 12-04-2001, 07:40 PM   #17
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Just a theory...

If you want to keep the RS tranny and rear end, I don't think that would be a problem. Just put the RS flywheel on the new block and I bet it will work.

If you want some help, let me know. Oh and if it matters, I'v already swapped my own engine so I'm pretty familiar with the process.

One more thing. If you want to do a write up and take lots of pictures, I'd be glad to put it up on my site.

Chad
93 1.8T
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Old 12-05-2001, 01:01 AM   #18
EddyRS
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I've been told that the RS Flywheel and the WRX flywheel are not compatible......I was hoping to do the swap (As I have a JUN Lightened) But I guess until I actually try and change the units I won't know. Another idea is to take the RS flywheel and modify it to fit on the WRX crankshaft. Don't know about the feasability of that thou.

One thing for sure....the WRX clutch will not mate up to the RS Flywheel (So the reverse is likewise).

This may be the greatest hurdle for this project.....I hope it doesn't bust me.

Cheers

EddyL.
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Old 12-05-2001, 01:36 PM   #19
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Eddy,

You'll be able to test this. I'm sure someone out there has an extra RS flywheel that you can borrow. You already have the motor, right? If so, just unbolt the flywheel and see if the borrowed RS flywheel bolts on. If it does, you can use the current tranny, if not... start smuggling money or selling yourself on the street for a WRX tranny and rear end.

Chad
93 1.8T
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Old 12-05-2001, 03:35 PM   #20
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The suggestion that the WRX trans would be required because of a clutch/flywheel incompatability seems a bit unfounded. Anyone care to enlighten me as to why the tranny cares which clutch/flywheel is installed? So long as the installed height of the WRX clutch/flywheel is the same as the RS, where exactly is the problem?

Keep in mind, the WRX has a completely different wheelbase than the RS so the transmission may not have the axles exiting from the same point, therefore eliminating any possiblity of easily swapping one for the other.
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Old 12-05-2001, 10:21 PM   #21
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catfish & eddy:

On the swap that I mentioned above, the owner used the entire WRX drivetrain: engine, trans, driveline & axles, rear end assy, and all four struts. Everything lined & bolted up up correctly to the older Impreza chassis.
To my unprofessional eye, both transmissions looked the same to me.

Just my $.02.
Paul
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Old 12-05-2001, 11:06 PM   #22
EddyRS
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The reason there WAS a problem was that the WRX flywheel will not mount with a RS clutch. I was told by the place where I purchased my JUN Flywheel that the Flywheel was not capatible with the WRX engine. So I have John @ Subaru/Suzuki try mounting a RS flywheel to the WRX engine......BUT .......guess what?

IT BOLTED RIGHT UP.

So I will be able to mount my JUN flywheel (RS-spec) to the WRX engine......AND in so bolt up my ACT clutch and RS tranny. This will aliviate me from having to buy the WRX tranny, drive shafts, rear diff, and clutch assy.....as well as a million other small bits and pieces.

So for those of you who do not have the cash to do a FULL swap of the driveline, just use the flywheel of the RS and toss or sell the WRX flywheel and Clutch.

QUESTION???

Now with more power.....a Lightened flywheel, and a ACT clutch....how long do you think the RS tranny will last with that combination????? Better yet,,,,do you think I should be getting another tranny for a spare right now

Yea....yea......I know....it is all determined by the driver, and how he or she shifts.

At least now I have a chance of making this happen........

Cheers

EddyL.
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Old 12-05-2001, 11:13 PM   #23
EddyRS
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I guess I learned a lesson today.....one that I should have known better.....

Take what people say with a grain of salt....

I got myself all worried about the Flywheel/clutch that I should have tested it first....then worry later. I guess I panic.....

Thanks for helping me see straight again.

Cheers

EddyL.
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Old 12-06-2001, 01:23 AM   #24
bobski
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Eddy,

How do the gear ratios compare between the RS and the WRX?

I wonder if driveability will be affected since the ratios may not be ideal for the WRX engine.
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Old 12-06-2001, 03:46 AM   #25
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How much was it for the WRX tranny/rear diff combo?
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