Out with the 2.0 and in with the 2.7 w/pics

[Adrenalin Rush]

Well I came back from the desert and was eager to start my swap so here we go. I have an 04 WRX that I pulled the stock 16K mile 2.0L out of to make room for an EJ22 2.65L. Many of you may have already read about this motor, it was assembled by Wes out in Reno for his 10sec drag wrx. My goal is to create the most powerful and fastest stock mount turbo wrx in the US while maintaining all of the creature comforts like AC, entertainment,etc. Why? Because everything else has already been done. Who holds that record now? I have no idea! I have combed the forums looking for that answer and I don't have an answer. If you have any insite on this subject, please offer it up. I am all ears. Now days, everyone is rotated. I mean I love a rotated WRX but they are so common. I want to build something different and sticking to a stock location turbo is what I want to do. How long will that last? Until I can not get another drop of horsepower out of it and when that happens, I will go another route or be happy with it. Who knows! The green I am using is my place holder for the FP Red. Here is some info on what I am swapping in:

Sept 2008 Changes The above plan has changed... I have moved away from the stock location turbo as the competition here in MN is pretty good. I have teamed up with fobiawrx and implemented his style of turbo location. This will net great spool on a twin scroll setup which I am now using. The FP Green has been replaced by a Garrett GT4088R. This of course changes the up and down pipe sections. Pics are posted later in the thread around page 4. More to come!!!!

May 2010 Changes: Things have progressed into a new direction, well not really, the is still that same "make power" but how this is done has changed. You can take note of the changes below in green and see what is going to surface. We are using some prototype items this time around so if you see something different or new, that is what is going on and we apologize for the lack of pics.This project has taken the back burner for some time due to the progression of the company but focus is now back to the task at hand. Who ready for some power?

Changes in red and green below

2.65L EJ22T with replaceable wet Sleeves
Heat coated + WPC treatment pistons
Crawford Rods
V7 Big Port STi Heads with +1mm valves and De-bured
Ported, Flow tested, Port matched with TGV housing, Exhaust Manifold
DPR Stage 3 Non-AVCS Cams
DPR Custom intake/exhaust valve springs
DPR Ti Retainers
Heat coated Exhaust ports
TGV Housing-ported and powder coated black
Polished Intake manifold
Aeromotive Fuel Rails (New)
Injector Dynamics ID2000 Injectors (New)
Fuelab Prodigy Fuel Pump (New)
Fuelab Fuel Filter (40 micron 10AN) (New)
Fuelab FPR (New)
Drentech Fuel Surge Container (New)
Turbo XS Fuel Rails (no longer in use)
UR 1000cc injectors with resistor pack (no longer in use)
Walbro 255 Fuel Pump
Ported Stock headers with heat wrap (no longer in use)
Fobia Fab Twin Scroll Header (New)
PE Timing Belt
TXS Front Mount I/C
FP 3” Green Turbo with FP stainless steel oil line (no longer in use)
Garrett GT4088R Twin Scroll Ball Baring Turbo(no longer in use)
Borg Warner S400SX3 Turbo (New)
Twin Tial 44mm Wastegates (no longer in use)
Twin Tial 38mm V Band Wastegates (New)
TXS Short Ram Intake with Perrin Silicone Intake Hose (no longer in use)
NGK Iridium Plugs (one stage colder)
Perrin Lightened Crank Pulley
ACT Street Lite Flywheel
ACT HD Street Disc Clutch
Goodridge Stainless Clutch Hose
AndrewTech PPG 5Spd Transmission (1-2ST, 3-4Heli) sloshing Motul 300 and Redline Lightwieght Shockproof
Megan Racing 4” Bellmouth Catless Downpipe (no longer in use)
Megan 3” Catback
Megan Catless UpPipe (no longer in use)
Koyo Polished Race Radiator (no longer in use)
Koyo Half Radiator (New)
Drentech Water to Air Intercooler (New)
Drentech WRX Water Reservoir w/ built in pump (New)
Drentech Heat Exchanger (New)
AEM TruBoost Controller
AEM Wideband AFR
AEM EMS (New)
Braille B14115 11.5lb Battery (New)
Spal Fans (New)
Cobb Street Tuner (no longer in use)
Cobb AccessPort (no longer in use)
Cobb Map Sensor Adapter
Zeitronic 3.5 Bar Map Sensor
5Zigen ZR+ 520 18x8.5 47offset
Megan Racing Coilovers (New)
255/35 Falken 452
Project Kics R40 Lugs

Visit the for sale thread here

There is more to the car such as suspension, wheels and such that I have not addressed but I will once I get to that point. Right now my focus is to get this thing together. I am sure someone wants to comment on the wheels, they too are a place holder for the 18x8.5's I will be running.

Visit our website for more pic and info. www.adrenalinrushllc.com

Now for some pics. Current Pics and video on Page 3 Even More pics on page 4 (HDR!!)
This my brand new, virgin, one day old WRX (Oct 2004)


Predeployment photo (Oct 2006)


Post deployment (Jan 2008) This is my EJ20, stripped and ready to come out. The method of flipping the AC to the right and PS Pump to the left worked like a champ!







Done for the night!

The swap was easy and did not take very long. Everything was pretty straight forward for the most part. Next up was getting the EJ22 ready to drop in. I had to tap the exhaust manifold for my EGT but that was a breeze. I swapped the fuel rails and relocated the injector resistor pack since I was going to run AC. The 2.0 went up for sale and sold quickly. It was pretty virgin and I had a ton of hits on it. I won't say who got it but I can tell you it went to Salt Lake City, UT

Now it was time to drop the 2.65L in. The tranny was still gone at andrewtech getting some gears so I decided to drop it a few days later. I had read about the 2 bolt starter issues and decided to tap the tranny case when it got back so I could use two bolts to hold it on. I will post picks of that when I get my tranny back. I am sure there are some out there that could use photo's of that. Maybe I will just do a write up. Anyway... in with the monster!

EJ22 2.65L with heat coated pistons and wet sleeves

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[Adrenalin Rush]

V7 Heads with heat coated chambers

TGV's port matched to the heads


Taking it off the engine stand.

Checking for clearance

She's in and wanted to lean forward, hence the rachet strap


All done with the hoist, fits like a glove!


Next up was the engine harness, heater hoses, vac lines, fuel lines and such. I labeled everything so the reconnect went smooth. I had already had the flywheel resurfaced so I put that on with the new clutch and stainless steel line.


Now lets talk about the turbo oil line. The V7 STi heads have a two way oil feed on the back of the heads. There is a banjo fitting that splits two ways, one to the AVCS and one to the turbo feed. I bought the stainless steel braided line from FP for my green and guess what, it did not fit. Now I ordered the WRX one not the STi one since I thought there STi one was for the 2.5L. After doing some research I found that the fitting from the V7 head is a 12mm male flare and the FP line was 4AN female. After searching nasioc I could not find any info about this so I turned to google and came across a fitting that was for the STi that was a 12mm Female Flare to male 4AN, BINGO!!! Here is the link for anyone that needs it. STi OIL FITTING It cost $19 plus shipping. Too easy. It arrived about 4 days later and fit perfect!

[Adrenalin Rush]

So I continued to assemble the motor after changing out some gaskets (throttle body, intake manifold to TGV, turbo to up and turbo to dp). Next on the plate was the radiator. Now I pulled the stock on and put it up for sale and off it went. To replace it I had a polished Koyo radiator. I mounted my fans to it and went to drop it in. It took a few minutes as the Koyo is definetly thicker but ended up slipping in just fine. I did notice however that the Koyo lacked the radiator cap near the top hose like my oem one. I search online some more and found that the 02-03 WRX don't have a filler neck there. I wondered for a minute how the older wrx's filled there rad's but I figured out a method.

Out with the old

In with the new


Now that the rad was in, I was pretty much done under the hood so I turned focus to the rest of the undone mods I wanted to. The rear bumper and lips had been in my parts room awaiting install so I decided to install them and do a write up. In you are interested in it here is a link. Rear Arch Install Here is a few pics of the finished product.




As for my center console, I have the 04 ugly console so I wanted to give the interior a face lift. I got a center console from ebay from a wrecked STi while I was in Iraq and it was time to install it. The swap is pretty straight forward and everything went together just fine. Some of the parts had some scratches so I think I am going plasti dip it black. We'll see. Here's a pic.



For my decklid, I bought a 07 LTD STi spoiler to mount onto my trunk. I have a factory spoiler so I pulled it off and got some quotes for filling the holes. I am not sure if I want to fill the holes and have it painted or get a bare lid and have it painted. I ended up having my holes filled and painting the lid. After it cured the spoiler went on. PICS HERE

Now the grill! I have been wanting to remove the pillar, so on saturday I cut it out, cleaned up the plastic with the demel, bondo'd it, sanded it and painted it. The color I used is PHANTOM GRAY from Dupli Color. It is such a perfect match! It was such a perfect match that I did not painted the whole grill because it blended right in!! Here's a pic for you.





In the area of audio/video and such, I use a kenwood double din unit with the Garmin 510 Nav harddrive. I also added the IPOD interface for the kenwood and it works like a charm so now I have 80GB's of music on tap or I can use my Iphone, it also will charge the Iphone. The factory system sounds good enough for me except in the subwoofer area. So I used to have a custom built sub enclosure that I made when I first bought the car in 04 but I ditched it for some love from Auto Integrations. They took care of me pretty good on a group buy for a fiberglass sub enclosure and hideaway amp rack. Thats right, I have pics! The install was so easy and I love fact that I have my trunk space back and a super clean install. Check it out!!

Sub and amp rack

Amp rack uncovered


Here are some more specs.
Triple Pillar Pod (one slot left) 52mm
STi Gauge Cluster with Subaru certified miles sticker prior to replacement (a must)
Defi BF Amber EGT, Boost, Oil Temp in the Defi Pod
Kenwood Double Din Head Unit 7015 with Garmin Nav G510 and Ipod interface
Kicker Comp VR12 DVC in custom box with Autotek amp
Optima Red Top Gel Cel
Rear View Cam in trunk key hole
Ebay Vortex Generator
07 STi Limited Spoiler
2005 STi Rear Bumper and Fender Flares
Gruppe-S JDM Front Lip
STi Hood Scoop
STi Sideskirts
Cleared Headlights with McCulloch 6500 HID kit
Powerslot Plus Front Rotors
Racing Brake Rear H6 Upgrade
HPS Pads
Tein H Sport Springs
Front and rear strut tower braces
Lower H Brace
Redline Hood Struts
Energy Suspensions Shifter Bushing
S204 Red Hazard Button
2006 STi Center Console with TR radio trim
5Zigen ZR520 18x8.5 w/ Falken 452 255/35-18
Fluids include Royal Purple in the engine, tranny and diffs. Redline Water Wetter for cooling.

[Adrenalin Rush]

I have the trunk back from the body shop. The holes have been welded and it has been repainted. I slapped it back on. I will put the 07 spoiler on soon and quite possibly an emblem, I am still thinking about it. It is a surprise and I am sure many of you will like it. Here's a pic.


Here are the original gears from the tranny... wow... something missing?

Subaru of America.... thanks for nothing...

No comment....


THE WHEELS ARE HERE!!!! 5zigen ZR520 18x8.5 with 255/35 Falken 452's and some kics r40 lugs, more pics coming of them on the car today!!!


Here is the first start up video on youtube CLICK HERE and some driving video

Some new teaser pics, I will shot some more in the daylight.

[kaos200]

holy ish son!
that's going to be one helluva step up.
Dog box or synchro?

[kenlee]

Nice! Time to shred some assfault. What kind of seats are those btw?

[rexworx]

You make me happy!

Great build!

[Adrenalin Rush]

Tranny is syncho.
The seats are stock 04 seats!
Thanks for the comment rexworx

[Ziggyrama]

If you're still considering EWG, go for it. If power is what you're after and you don't care that much about noise, it's a no brainer.

Since you'll be pushing some serious power out of this build, I am questioning your headers at this point especially since you'll be cammed. Your exhaust efficiency will be key to really make the cams work for you. Generally the P&P stockers are good for a while but you may actually see some gains from moving to perhaps something a little more optimized like equal length design or something close to it. Just something to think about.

Lastly, since you've got a lot into this build already and your internals will be strong, consider adding alcohol injection as well. It'll keep things clean and you'll see major gains on top of what you already have. I think that would really take advantage of all the internal work you have done. Great job!!!

[Adrenalin Rush]

Ziggy, thanks for the info. EWG is a must and I am basically deciding which style and brand to go with.

[Homemade WRX]

looking good!!

[Devan M]

Cool project.

I thought that shortblock was an R4 from Crawford not an R3

[javid]

Interesting build.
However, you're gonna need a larger turbo to achieve your goal.

I would suggest an EWG MZ72 from deadbolt, 44mm tial with a 15 to 20psi spring.
My 10psi spring will only hold about 28 psi at max duty on my SZ60.

[mick_the_ginge]

What is the goal again?

I've made over 520 WHP (mustang dyno) with an FP Red on C16, all boost, 30 psi. I would not push a red more than that.

[javid]

his goal: "My goal is to create the most powerful and fastest stock mount turbo wrx in the US while maintaining all of the creature comforts like AC, entertainment,etc."


Mick, what have you trapped with that setup?

Why wouldn't you go past 30 psi?
Did you try and not make any power?

[mick_the_ginge]

Not my car and I don't think they ever drag raced it, I was just tuning it. (UTEC)

The person wanted 500 WHP, I got them 500 WHP and stopped. This has got to be about 2 years ago now, (6/21/2006 to be exact, i still have the logs) at that time 500 WHP was alot of power. Stock cams, stock heads, Crawford S2 block (which is just pistons I think)

It was a MAF based tune (before UTEC SD) and only using the stock MAP sensor so it was pegged and I was tuning one column. MAF volts were at 4.9 with a Perrin BigMAF.

[javid]

Originally Posted by mick_the_ginge

Not my car and I don't think they ever drag raced it, I was just tuning it. (UTEC)

The person wanted 500 WHP, I got them 500 WHP and stopped. This has got to be about 2 years ago now, (6/21/2006 to be exact, i still have the logs) at that time 500 WHP was alot of power. Stock cams, stock heads, Crawford S2 block (which is just pistons I think)

It was a MAF based tune (before UTEC SD) and only using the stock MAP sensor so it was pegged and I was tuning one column. MAF volts were at 4.9 with a Perrin BigMAF.

That makes sense but this guy has all the bells and whistles to run a large stock location turbo at full tilt. I wouldn't be surprised if my sz60 could make 35 psi in the mid range so long as i had the long block (i believe the valves start to float past 32 psi or so), EM (map based), and EWG spring (20 psi) to hold all that boost together.

[Paintballguy]

holy pistons batman!

badass motor

[Jstyles21]

Outstanding Build, I wish you the best of luck!!!!

[Dobbs]

amazing... subscribed... and thanks for the help in the desert!

[jordanderson]

awesome car, is it your daily driver?

[Adrenalin Rush]

Originally Posted by Devan M

Cool project.

I thought that shortblock was an R4 from Crawford not an R3

It was a BRAND NEW Crawford R4 in a NEW EJ22 block. Then it got sent to DPR and he took it apart, spec'd everything, heat treated the tops of the pistons and did a WPC treatment on the skirts ( its a bad ass metal friction treatment they do on F1 cars) gapped the rings ect, then reassembled it. As far as the head, they are JDM big port heads that were:
Ported to hell and back
De-bured all the surfaces
added more oil galleys to oil the cams better
Heat treated the exhaust ports
DPR stage 3 NON-AVCS cams- Idle around 1000 rpm
Ti retainers
Custom valves and springs
Correct valve lash settings

Thanks for the comments guys and it is my daily driver. I know... I'm crazy... As for the turbo issue, I have looked at many options and the red looks good for me now. However, I will continue to research until it is time to swap my green once any and all bugs are worked out. In the EWG area, I am considering the synapse wastegate. I waiting for an undisclosed party to furnish me with info about their deal with synapse. I love the design and I am interested to try it. I love the input from the different walks of life here on nasioc so keep it coming. Thanks to all with positive input. Aj

[Cheveyboy]

looks great!

Might I ask as to the source of the 02 radiator... As im trying to find that specfic fit.


Thanks

[jigga]

Originally Posted by Cheveyboy

looks great!

Might I ask as to the source of the 02 radiator... As im trying to find that specfic fit.


Thanks

contact Mike at Innovative Tuning. He will get you that particular one.

[Adrenalin Rush]

UPDATE: Still waiting for the transmission to return from Adrewtech. It has been gone since JAN 10th. There was a problem with the gear cut on the 3 and 4 so they had to send them back to PPG and get new ones. I would like to fire the car up the first week of March since I should have already had it on the road and tuning it. I'm so excited to get this thing running.