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Old 04-04-2007, 06:32 PM   #1
Jutboy
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Question Jutboy's EJ22(T) Build Thread

Alright, lets me start off by saying, I know there are a bunch of these threads out there already and I'll try not to repeat them....I'll try....I really have spent about 6 or 7 hours reading about this topic over the last two nights....that doesn't count the hundred some-odd pages I printed out and read at work. Seriously, I'm starting to lose my mind....

So quickly, I just bought a 91 Legacy Turbo, before I register it I want to yank the engine and do some simple/effective/inexpensive mods to it....I'd be happy with around 350 whp and realiablity is a big deal to me.....

So everyone seems to say throw some 2.5 heads on it and a decent turbo....easy right?

My questions

1)How easy/hard is this, I've rebuilt classic engines (pre-80), but nothing liek this, nothing with turbos, I don't want to get myself into a huge problem, the car runs fine as it is.

2)The heads.....SOHC or DOHC? Phase I or II? I'm having trouble understand which actually will match up properly, are there a certain year/model ranges that I need to get...any that I don't need to do any machine work on to get them to mate?

Also are the SOHC non-interference...that seems like enough of a reason to go with them........

3)The Intake.....I'll need a new one for the heads, does this bolt on easy enough? Do I have to fab something up?

4)The wiring.....As long as I keep the hp to a reasonable rate can I keep the same ECU? Are there any sensors for the heads/intake that I have to worry about?

5)The fuel.....Does the injectors depend on the turbo I get? Im assuming 550 cc should be enough right? Also I'm going to have trouble running my fuel rails?

6)The Turbo, I found some good suggestions on which ones to get but none mentioned how it will fit into my engine compartment/down-pipes.....I'd rather not waste lots of money/time fabricating pipes.....if I can even pull it off.

7)Is there anything I'm blindly ignoring, I'm trying to be good and not just dive into a project.

7)ANYONE THAT HAS ANY PARTS PLEASE PM ME!!!

8)ANYONE THAT IS WILLING TO CHAT WITH OVER INSTANT MESSANGER CLICK ON MY LITTLE SYMBOLS OVER ON THE SIDE!!!! I won't bug you much but it would be nice if I had a quick question...

THANK YOU SO MUCH -Justin
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Last edited by Jutboy; 04-04-2007 at 10:13 PM.
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Old 04-04-2007, 11:52 PM   #2
mybluesubi
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1)How easy/hard is this, I've rebuilt classic engines (pre-80), but nothing liek this, nothing with turbos, I don't want to get myself into a huge problem, the car runs fine as it is.

It's not that hard. It's more time consuming than anything. Just don't rush it and get all your torques as they should be and you should be fine.

2)The heads.....SOHC or DOHC? Phase I or II? I'm having trouble understand which actually will match up properly, are there a certain year/model ranges that I need to get...any that I don't need to do any machine work on to get them to mate?

SOHC or DOHC depends on what kinda air flow you want mostly. The phase I and phase II EJ25 heads both have dual exhaust ports so it would be easier to find a header for them. The DOHC EJ25 heads were phase I, built in 98. The SOHC EJ25 phase II heads were built from 99 and up. Don't quote me on this but I believe all the EJ22's were SOHC. They will all match up properly. There should be no machine work that needs to be done to match your EJ22T block to any of the heads up through I believe, 2001.

3)The Intake.....I'll need a new one for the heads, does this bolt on easy enough? Do I have to fab something up?

If you use the phase I heads (DOHC), your intake mani should fit fine. I would recommend using the intake mani from the phase I heads.

4)The wiring.....As long as I keep the hp to a reasonable rate can I keep the same ECU? Are there any sensors for the heads/intake that I have to worry about?

You shouldn't have any problems with your stock ECU being that it was programmed for a boosted engine anyways. You will later on want to get it tuned after you get it all together just so the computer knows everything you have and will know the right timing/air fuel mix and other parameters of the engine. The only sensor that has to do with the heads is the camshaft sensor on the left head. All of your sensors should work.

5)The fuel.....Does the injectors depend on the turbo I get? Im assuming 550 cc should be enough right? Also I'm going to have trouble running my fuel rails?

I would highly recommend using 550's or STi "pinks". Your fuel rails should not be a problem using although I can't be certain that the pinks will fit in your stock rails.

6)The Turbo, I found some good suggestions on which ones to get but none mentioned how it will fit into my engine compartment/down-pipes.....I'd rather not waste lots of money/time fabricating pipes.....if I can even pull it off.

I'd personally recommend getting an STi stock turbo. As far as up pipe, downpipe and header are concerned, go aftermarket. Especially if you are planning on running a lot of boost and going for a lot of power. 3 inch exhaust would be highly recommended as well.

7)Is there anything I'm blindly ignoring, I'm trying to be good and not just dive into a project.

Take your time, be patient and get it tuned after you're done.
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Old 04-05-2007, 03:27 AM   #3
redwagon
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I think you could stand to look around this site: http://bbs.legacycentral.org/
They certainly have tried just about every combo of injector, intake and fuel rail you can think of.

EJ22T + Phase I DOHC heads + thinner Phase II SOHC gasket = 8.0:1 compression. Very popular mix of parts.

For a long time it was taken as gospel that a SOHC ECU could not run on the sensor input from DOHC heads. Now some of the EJ18 guys are running DOHC heads off the stock ECUs, so this may also be possible on your ECU. You may consider an emanage to control the larger injectors you are going to need to run. These older ECUs respond well to tweaking with piggybacks.

Given the age of the car you might want to upgrade your fuel pump.

Last edited by redwagon; 04-05-2007 at 03:22 PM. Reason: kaint speel
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Old 04-05-2007, 12:27 PM   #4
IllNastyImpreza
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my original build plan was the ej22t block with my phase 1 DOHC heads....

YES they will bolt on...
The DOHC heads have larger ports, meaning they have a higher potential for HP....BUT
the DOHC heads are ZERO tolerance heads...meaning that if you snap your timing belt, or whatnot....your valves WILL hit your pistons.

I'm running the DOHC heads due to the fact they came on the car...and It requires basicly no wiring...

but since you have a choice.... why don't u grab a set of JDM big port heads?

If I where you I would just run a stand alone ECU anyway...

and for a decent turbo...you will have a verry hard time pulling off 350 whp with a stock sti turbo...

there have been a bunch of vf23's from the JDM cars popping up lately...
(same as vf22 but with a faster spool) you could definatly squeez 350whp with a proper tune...these should bolt right on

as far as fuel goes...the yellowtop STI injectors are sidefeed, and will bolt onto 98 rails... the WRX injectors are topfeed and will bolt onto the 99-01 rails... I'm not quite sure 550's will be enough though(you might as well have them modded to the 820's)

btw...where are u located?
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Old 04-05-2007, 05:34 PM   #5
Jutboy
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So the vf23 will bolt on easy enough? I won't have to fabricate anything?

Wheres the best place to get a standalone ECU? Is it possible to run a low boost setup until I get the money for one, things are little tight now....or as mybluesubi stated, get my current ECU reprogrammed?

Where would I get this done and can someone point me to some good resources on tuning?

Thanks much - Jutboy

btw. I just updated my profile, I'm from Andover, CT
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Old 04-06-2007, 12:26 PM   #6
NicFunkadelic
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nice, more AFI builds in CT!!!

Don't get your hopes up too high about not having to fabricate anything, pretty much any heads you swap onto the ej22t block will require some "massaging" to make fit. I went through this, basically other cylinder heads are larger front to back, and will cause clearance issues with the up-pipe as it comes up around the back of the pass. side heads. It's not a huge deal, but you gotta get creative to make it all fit together.
Sounds like you got the rest pretty well figured out.
Good luck, and feel free to give me a buzz for some help.
Nick
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Old 04-06-2007, 12:31 PM   #7
turboL
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ugh I wish I would have kept my 22t block, shrug.

good luck with the build!
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Old 04-06-2007, 12:50 PM   #8
IllNastyImpreza
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Quote:
Originally Posted by Jutboy View Post
So the vf23 will bolt on easy enough? I won't have to fabricate anything?

Wheres the best place to get a standalone ECU? Is it possible to run a low boost setup until I get the money for one, things are little tight now....or as mybluesubi stated, get my current ECU reprogrammed?

Where would I get this done and can someone point me to some good resources on tuning?

Thanks much - Jutboy

btw. I just updated my profile, I'm from Andover, CT

yea the vf23 come stock with the ej20g I believe...so its the same flanges.

you should surf the Engine managment forrums as far as that goes...its a vast subject with almost endless options... Being as your OBD1 you are a luck SoB you can chose basicly ANY ecu you want...and STILL pass inspections...

alot of the standalones have wideband o2 settings that will basicly tune themselves with the use of a wideband oxygen sensor.(just to get you up and running) And New england has a few tuners capable of dyno tuning your car( to dial it in) xx tuning is actualy located in CT. And Dent sport garage is nearby in Norwood Mass....

good luck with the project...I'm sure you have your work cutout for you !
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Old 04-07-2007, 06:24 PM   #9
Jutboy
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I just wanted to share an amazing artical "Wedge" shared with me....

http://legacycentral.org/library/lit...e/headswap.htm

I'm am a little confused about the oil/coolant issue.....heres what he says

Quote:
Then finally, the right side 2.2T cylinder head has 3 holes for the turbo oil supply, oil return, and coolant return. Also a right side camshaft support has been added to the 2.2T turbo engine in order to supply oil to the turbo and return coolant from the turbo. Guess what's not on the 2.5 head. Right, it could be made to work though. There's an oil plug on top of the block towards the back, and you could tap into the heater hoses or something for the coolant return, and the heads still bolt right on! But remember, I'm wanting to enhance my turbo engine, not bolt on something and then have to adapt ten other things to make it work. To me that's not an enhancement it's a regression. Strike four.
So for the coolant you just bypass the block+head and just tap into the lines appropiately.

The oil you just use a plug on the top towards the back.
Just that simple or I'm missing something?

I was leaning towards getting the SOHC heads for inference reasons and dont know if theres a difference between the Phase I and II

Thanks again - Justin
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Old 04-07-2007, 06:49 PM   #10
Wedge
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That is a great article, Justin. But I don't take credit for it cuz I didn't write it.
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Old 04-07-2007, 07:52 PM   #11
Jutboy
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Last edited by Jutboy; 04-08-2007 at 11:44 AM.
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