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Old 05-13-2011, 05:43 AM   #1
weirdpuffy
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Join Date: Feb 2008
Chapter/Region: SCIC
Location: Orange County
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2001 2.2 WRXRS
Silver Thorn Metallic

Default GC Engine Swap: Tearing & Rebuilding EJ205

Hey Guys,

I own a 2001 Subaru Impreza RS. I know my post count is extremely low, but i usually spend half of my time on nasioc and on rs25. Most of my comments, threads making, ads are on rs25. Here is my members journal/blog for my impreza coupe, if anyone is interested: http://www.rs25.com/forums/f145/t156...ml#post2455630

I just recently bought a somewhat complete 04 EJ205. In order to save money, I decided to do the swap on my own with of course help from my skilled mechanic friends. I am not really knowledgable about the ej205 and what parts go where or things to do.... so please bear with me.

Heres is my plan as of right now:
  1. Bought Ej205
  2. Tear Apart The Engine to Find Out What Needs To be Addressed
  3. Collect OEM Parts: Complete Wiring Harness, ECU, Gaskets, Seals, ETC....
  4. Buy Aftermarket Parts: Forged Pistons & Rods, Race Bearings, APR headstuds, STi Crank, Garret GT28 or any VF (maybe), etc
  5. Once Collected, Install Items into Engine & Other
  6. Set the Car Aside for 3-8 days
  7. Tear Apart Dash and Send RS & WRX wiring to I-wire (shout out to them )
  8. Swap out the RS engine, then Swap in the freshly rebuilt WRX engine
  9. While that is happening, calculate what my expenses are...
  10. Once I-wire Sends back Merged harness: Install it, connect everything, return and bring car back to normal
  11. Diagnose any problems
  12. ....(Sorry So Much To Add To the Check List)
  13. ....(Sorry So Much To Add To the Check List)
  14. ....(Sorry So Much To Add To the Check List)
  15. ....(Sorry So Much To Add To the Check List)

So with that being said, i have pictures pictures pictures!
I am trying to find out what parts i have missing in order to complete the engine.

I think or know i am missing: stock flywheel, tmic, idle air control valve, stock airbox, power steering reservoir, etc.

Can you guys help me out? Or confirm the missing items?

Here is my engine i just picked up:



















Oil Pan, Pickup Tube, Pressure Plate (transmission), Throttle Body (missing ICAV)





It is late, so i might be forgetting a couple words or sentences. I will add more or edit this thread later on today. Thanks for the help
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Last edited by weirdpuffy; 05-13-2011 at 03:54 PM.
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Old 05-13-2011, 05:44 AM   #2
weirdpuffy
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Silver Thorn Metallic

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Side-by-Side Comparison (EJ205):





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Old 05-13-2011, 10:35 AM   #3
Wrex20
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Coolant tank is missing that sits on the intake manifold. Be sure to get the manual and plastigage the engine when putting it back together. want to keep the factory tolerences. The aftermarket pistons will have different tolerences than stock pistons though. So make sure to hone the cylinders to the correct specs for the piston you order. Buy an entire engine gasket kit too. This will include every gasket needed to rebuild your engine and is way cheaper than buying everything seperate. I got an entire engine gasket kit for around $200 on ebay. I think the dealer is just a bit more expensive than what I paid for mine.
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Old 05-13-2011, 01:05 PM   #4
weirdpuffy
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Yeah oh I got it confused...ima newb. I thought the coolant tank was the power steer g
reservoir.

Yup I will plan on doing that, boring out the heads. But I am in the first stage of just making sure everything is there on the engine and also if the block is fine before I start laying down serious cash for this project
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Old 05-13-2011, 03:53 PM   #5
weirdpuffy
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thanks for moving my thread mods

bump!
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Old 05-13-2011, 08:01 PM   #6
jamesfacts
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black & blue from parking

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Looks pretty good to me. You're also missing the ps lines / reservoir, BOV, driver's side IC bracket, PCV breather system, boost controller / lines and a couple other little things.

You want to re-use your GC AC pump, flywheel and clutch. I'm parting out an EJ205 (w/ a stage 4 VF30 setup) - let me know if you could use anything.
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Old 05-14-2011, 11:29 PM   #7
weirdpuffy
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Last edited by weirdpuffy; 05-17-2014 at 04:08 AM.
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Old 05-14-2011, 11:30 PM   #8
weirdpuffy
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organized the garage. Kind of a neat freak






this was probably the hardest thing to do so far through this whole engine tear down process. I spent an hour looking for something long and strong enough to withstand the amount of pressure and stress of me trying to loosen the bolt. Eventually, i bent 2 flat heads (on the front side) trying to break the bolt free. Then went to the other side, and grabbed two more flat heads and a long ass 1/2 extension and thankfully was able to break it free. man was i really happy :drunk:
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Old 05-14-2011, 11:31 PM   #9
weirdpuffy
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Ok then i ran into a minor road block again. I was removing all the cam gear bolts using a 10mm hexbit, then all of suddenly i snapped it. Took about 30 minutes to go to lowes and replace it with another. Lowes lady informs me that they wont be carrying hexbits anymore so if i break another one of these in the future i have to buy snap ons or craftsman. :wtf:
eff lowes:monkey:
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Old 05-14-2011, 11:31 PM   #10
weirdpuffy
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timing belt tensioners gone and cam gears gone. need to remove water pump still








see some minor surface rust on valves. should be fine on the inside. well just have to wait and see once i remove the heads.




Overall, i got a lot done today. I havent removed the heads, but from i am seeing, everything looks good so (internal wise). ive never had experience tearing apart an engine, let alone a subaru one, and this is by far the easiest thing to do so far other than having your friend trying to cooperate with you bleeding the brakes haha. Man, if its this easy, i may have to take my engine out more in the future. Ill keep everyone posted with more pics tomorrow.
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Old 05-15-2011, 09:40 PM   #11
winterfourever
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Subscribed! Might be doing this pretty soon
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Old 05-19-2011, 04:00 AM   #12
weirdpuffy
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driver side head finally off!





i never knew the stock wrx pistons had a dish like this. interesting. Looking inside the cylinder walls, it still has a cross-hatched pattern meaning the block is still brand new right?


addressing the passenger side heads.
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Old 05-19-2011, 04:01 AM   #13
weirdpuffy
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heads off, and i discover blown head gasket
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Old 05-19-2011, 04:01 AM   #14
weirdpuffy
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notice scoring on cam journals. what do i need to do to fix this? Anyone?
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Old 05-19-2011, 04:02 AM   #15
weirdpuffy
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tried getting off that stupid cover in the back where the flywheel use to sit. I chewed out a screw, but was able to get the rest. Need a bolt extractor







Overall i am down to last step of splitting the block in half.

Steps left to do:
  1. Remove chewed up screw on the plate cover that sits behind flywheel
  2. Need to buy 14mm hexbit to remove bolts
  3. Need to remove pistons
  4. Need to tap block and split

Hopefully crank bearings remain in good condition. I will take the block to a mechanic later on today or tomorrow. Have them inspect and diagnose the severity of the heads,cylinder walls, and scoring on cam journals. Cylinder walls are aluminum and all it needs is some honing down to it, right? As for the cam journals, i dont know :/
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Old 05-19-2011, 11:51 AM   #16
icky
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I respect your determination but this may be something you should at least watch someone do before you atempted it. I know you want a 2.5 crank so if you plan on selling the 2.0 crank, be sure to retap the flywheel bolt holes, you probably destroyed them. So you dont destroy your new sti crank, put the flywheel on and wedge a piece of wood between the case and starter ring; or buy an inpact driver.
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Old 05-26-2011, 02:36 PM   #17
weirdpuffy
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So this is going to be a long long post. Damn nasioc only lets me post 10 pics each post. But at least i am glad i am finally moving onto the next step of my project.





$95 not well spent. Bolt extractors were definitely helpful. Duck nose needle pliers not needed and 4 hex bit sockets were $39. Finally glad to be able to removed the chewed up screw. Like my home-made cheater pipe? :blowingup




First attempt

Second attempt

Last attempt

So took out all the cir-clips and needed to get the @#$%^& wrist pins out.
Used the 4 piece hook set from sears (only $8). Tried to fine bend the tips, which ended snapping them trying to get the wrist pins out. Didnt bother to take much pics as i was getting frustrated by this point and there was no way i was going to spend over $50 for a subaru tool. Gave up on doing it myself, and took the block to Outfront Motorsports, which was literally 10 minutes away from my house.

Last edited by weirdpuffy; 05-17-2014 at 04:09 AM.
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Old 05-26-2011, 02:36 PM   #18
weirdpuffy
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Old 05-26-2011, 02:38 PM   #19
weirdpuffy
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Old 05-26-2011, 02:39 PM   #20
weirdpuffy
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Old 05-26-2011, 02:39 PM   #21
weirdpuffy
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So brought the block to outfront along with the heads to get the cam journals checked out. First time meeting Ron, Jeremy, and Steve which btw i was fortunate of meeting since i dont really run into many friendly tuner or mechanics. Ron [mechanic @ Outfront] took the wrist pins out under a minute. I had him look over everything [heads, cylinder walls, pistons, rods]. Lets make it simple:

Good-
1.)cam journals are fine, all it needs is really fine fine sand paper or can be ran like that either way
2.)I was right! Ron inspected the cross-hatched patterns on the cylinder wall and assumes that the block is somewhat low mileage.

Last edited by weirdpuffy; 08-24-2011 at 05:16 PM.
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Old 05-26-2011, 02:40 PM   #22
weirdpuffy
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I dont think i mentioned it yet, but over the weekend i found a vendor/dismantl(er) on socalsubies. S&S Autosports ran by Aaron. Met up with him today to pick up a complete wrx wiring harness with ecu. He dismantles subarus and saabs. Great guy who knows his stuff about subarus.

Come to think of it, there are only two main suppliers of subaru parts that sell to the public (engine, tranny, drivetrain, etc). Those are silver line and y2kimports.com, both out of state. Glad to finally see someone doing it in Southern Cali.


Here's his business card




finally found one
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Old 05-26-2011, 02:53 PM   #23
weirdpuffy
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So picked up my block yesterday from Outfront. Nice crosshatched pattern and cleaned block . Also picked up mahle pistons (4032), new nitrided STi crank, and complete OEM subaru gasket kit.







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Old 05-26-2011, 02:54 PM   #24
weirdpuffy
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interesting...same dish style




Talked to some mechanics about the wrx crank, pistons, and rods and they said its fine. Nothing really wrong with anything except that stupid rust on the cylinder wall. There was rod knock but not so severe as i expected.
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Old 05-26-2011, 02:55 PM   #25
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all oiled up
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