Motor build fun!

[fastenova]

Hey everyone... I've decided to add some zing to my motor while I'm replacing it with the lower mileage one (83k). I am shipping my cams off today to Delta Cam in Tacoma to have them do a stage 1/mild grind on them.

After I get them back I'll be adjusting the valve clearance to factory spec, having the heads tanked and checked out at the machine shop, resealing the motor with new seals all around and dropping it my GT. Anything else I should have done while it's out? I don't care to go into the bottom end at all.

Supporting mods are Borla headers, Stromung HF cat pipe, custom catback with a Magnaflow muffler, Grimmspeed intake spacers, custom cold air intake, and most importantly, the throttle body bypass!

I've also done all the suspension and drivetrain goodies, LW flywheel and pulley, poly bushes everywhere and dropped about an inch all around. I'll also be installing my new 06 WRX wheels with new rubber, a custom fiberglass sub setup, replacing the tired window tint, and a few other goodies for fun.

I'm hoping to have around 200HP at the crank, but I won't know since I don't really plan on dynoing it real soon. It should be a lot more fun with the cams and a lower mileage motor though!

My old motor had 200k hard miles on it when it died. I'll post the results of the autopsy later

Aaron

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[Jonathan]

This is the Motor out of the '96 Legacy Outback that you are just getting through parting out ?

This was the first year of the EJ25, although I thought the EJ25 was only sold on the Automatic Outbacks, and the Outbacks with standard transmission stuck with the old tried and true EJ22.

I think Patrick Olson did similar mods to his '97 Legacy GT, although he had Cobb redo his entire DOHC heads along with their cams (back when they were still working on the N/A EJ25), and he also got some Air Fuel mixture modifications (a pickbacked controller ?) so that the motor wouldn't run so rich at high engine RPMs. My memory was that he got ~112 BHP Wheel Horsepower on his dyno runs.

[Huffer]

Aaron, sounds like fun!

[fastenova]

Originally Posted by Jonathan

This is the Motor out of the '96 Legacy Outback that you are just getting through parting out ?

This was the first year of the EJ25, although I thought the EJ25 was only sold on the Automatic Outbacks, and the Outbacks with standard transmission stuck with the old tried and true EJ22.

That may be the case, but the car I'm parting out is actually a '98. And, I already stuffed a 5 speed in my car which came from a GT of the same year, so no worries!

Originally Posted by Jonathan

I think Patrick Olson did similar mods to his '97 Legacy GT, although he had Cobb redo his entire DOHC heads along with their cams (back when they were still working on the N/A EJ25), and he also got some Air Fuel mixture modifications (a pickbacked controller ?) so that the motor wouldn't run so rich at high engine RPMs. My memory was that he got ~112 BHP Wheel Horsepower on his dyno runs.

Pat's car is one that has inspired me to do cams on my car! I remember about four years ago reading about his car and drooling. I graduated college and finally have some money to put into the car, so I am doing the things I've wanted to do for years with this car.

I am going to run without EM for the immediate future, that was one reason I went with the mild cam grind as opposed to the more aggressive one. I figure I can always add something later, and since I don't know what my plans for the car are, I don't want to buy something now that won't meet my needs in the future. Hopefully I'll still have a lot of fun with the cams without a fuel controller.

112 WHP seems low, as these cars have 165CHP from the factory, and figuring roughly 30% loss, that would be about 115 WHP stock. If I did indeed add 35 ponies with exhaust and cams (is that too much?) at 30% it would be more like 140WHP.

So either my loss numbers are too optimistic, or my power gain expectations are EXTREMELY optimistic! Pat, care to add anything?

EDIT: I found Pat's dyno graph here, and the biggest differences are that he was running a piggyback A/FC with ported heads. Otherwise we've got pretty similar setups - stage 1 cams, full exhaust with UEL headers, intake, flywheel. But the AFC and ported heads probably make a decent difference - I was figuring 20-25 HP difference. That meshes well with my 140WHP expectation, I think.

Pat, did you dyno before you did the ported heads and SAFC?

Cheers,
Aaron

[jey]

The S-AFC can be had for like $125-150 on Fleabay and it's actually very easy to install. I would think it's worth it.

[fastenova]

So besides the CELs I'm getting, and the very rough idle, this motor has really come alive! I am feeling awesome gains throughout the powerband, as Delta promised. It pulls all the way to redline, and has WAY more torque at highway speeds (60-80 MPH), in higher gears.

With four people in the car (~700 lbs) it feels like it used to with just me in the car (~200 lbs). When I'm alone, it flat hauls!

The idle, when it's not running rough, sounds great. The motor definitely makes a bit more noise and sounds amazing. Under load this thing sounds like a bat out of hell! In fact, I might have to rework the exhaust to get it a little quieter

It's a lot more fun to drive. Mileage so far is very poor but I attribute that to the intermittent misfires more than anything else. Once that goes away I should still be getting low to mid 20s and maybe upper 20s on the freeway.

Aaron

[Huffer]

Did you port the heads while they were out?

[Huffer]

Did you port the heads while they were out?

[fastenova]

Originally Posted by Huffer

Did you port the heads while they were out?

Originally Posted by Huffer

Did you port the heads while they were out?

No, and no. I didn't have the cash and I have another set of heads that is in slightly better condition that I may have PnP'd later.

[NJ Legacy]

makes me wish i had money to rebuild my motor lol

[Reason01]

The EJ25D stock whp is lower than 115. Maybe 95-105whp tops.

[Kansei]

well thats just rediculous as the ej22 had 135bhp stock...

are yall sure thats right?

[Reason01]

That's at the crank. I'm talking wheel horse power. na EJ22 is AROUND 80whp.

[Kansei]

well that sucks..... I thought it was much better than that.....

[Reason01]

Different type of dynos will give you close but different results. Also humidity, elevation etc are factors too. Check out the dyno thread on SLi to see what some people got. One member has 135 whp and he has a good amount of work done. If you plan on building a EJ22E you better wake up from that dream quick.

[Kansei]

is that the single port EJ22?

[peugoby]

Aaron once you get the misfires & stumbling idle figured out I need to go for a ride in it! Sounds like it hauls. Glade to hear its coming together.

[REWZ]

Maybe I missed it? you have pics of the autopsy, I want to see.

[fastenova]

Originally Posted by REWZ

Maybe I missed it? you have pics of the autopsy, I want to see.

I haven't had the time to tear too far into the old motor yet, as I'm still trying to get the new one running smoothly.

[REWZ]

Ahh.. sorry, I assumed re-build. Good luck!

[fastenova]

Originally Posted by peugoby

Aaron once you get the misfires & stumbling idle figured out I need to go for a ride in it! Sounds like it hauls. Glade to hear its coming together.

In trying to get rid of the CEL, I "Accidentally" upgraded the ignition coil to an MSD 8239 (per the DIY thread over on sl-i.net) and installed a AFC-Neo.

I didn't get rid of the CEL but it's pretty quick! Hit me up sometime, we'll go for a ride.

I also just got some JDM projectors in yesterday. =]

Aaron