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Old 12-23-2011, 10:50 PM   #126
PHATsuby
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2001 Legacy GT back
to stock is a project too

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Old 12-24-2011, 12:21 AM   #127
STIdarkside
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Congrats on getting it started.

I imagine you have some small things to fix still, but I imagine you are dying to drive it.
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Old 12-24-2011, 12:53 AM   #128
fibuz
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omg finally
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Old 12-24-2011, 01:27 AM   #129
PHATsuby
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to stock is a project too

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thanks, yea still quite a few things to figure out. I have yet to tackle the gauge cluster as you can see. I realized I don't have the starter interlock relay since it is only on MT's so it wasn't on my other harness. I had to use a jumper to bypass the relay and then it would crank over. I was also missing the interrupt relay so there is no way it would have started without that either since I had the security control module hooked up.

Once I plugged my fuel pump in it primed as it should, I built up pressure a bit and it still didn't fire up right away. After this vid I started it up again but it didn't start right back up so I'll have to determine if it is just from it being cold or something more serious.

Naturally I have to wait till monday to go see if the junk yard has that relay. I also discovered that the keyless entry module is different from 01-02 to 03-04 so I need to buy one of those.

Other electrical issues include:
no power to front seat
no power to door switches which I find odd because the door harnesses are hooked up so clearly there is some issue there.

Next time I work out there I"ll do some more trouble shooting and see what I can figure out. I'll warm up the garage a bit too and see if it helps starting.

The last thing I noticed/am concerned about is that the fuel pump seems to clunk on priming and my fuel gauge says the tank is full, but that could still be an issue of grounding/power so I won't worry about that just yet.

Ben

Last edited by PHATsuby; 12-24-2011 at 01:38 AM.
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Old 12-24-2011, 10:56 AM   #130
STIdarkside
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Well hopefully you get it all sorted out...

Looking forward to hearing your impressions and reflections on the swap.

BTW, your pm box is full.

Last edited by STIdarkside; 12-25-2011 at 09:57 PM.
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Old 12-26-2011, 01:24 AM   #131
PHATsuby
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Yea I figured it out, looked at he diagrams and had to plug in one plug and the seat worked. Then I went to try the windows and they didn't work so I was like WTF. It then took me 15 mins looking at wiring diagrams until I remembered I didn't have the key on. It helps to have power to windows you are trying to use. The seat moves without the key so I kind of forgot about putting the key in for the windows lol. It's been a long process.

I took the front seat out, naturally the last bolt was totally seized so after liquid wrench and some heat from a MAPP torch it finally came out.

We'll see how much I can accomplish tomorrow, things are pretty close now, with the major hurdle being the gauge cluster wiring to figure out(which I think I have) and actually wire them and test them. I'm still concerned about the starting issue but I'll see if it continues after I have all the little random grounds bolted down and get the actual starter relay I need tomorrow at the junkyard hopefully.

I definitely have leakage around my cat back exhaust gaskets so I may need to do something about that but it's not a huge concern at the moment.

I'm hoping I can to a point where the under side of the car is done in terms of the suspension and brakes are all bolted up. I am also going to try and get my carpet swapped out for the new one I have so I can get my seats back in and it will finally start to look like a car again.

I will need a keyless entry module so I"ll order that this coming week and really try to finish the car the next full weekend I can come down, which will be in January some time.

Ben
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Old 12-26-2011, 03:00 AM   #132
RooTBeeRthe1st
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Sweet! It LIVES!!! haha
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Old 12-27-2011, 01:32 AM   #133
PHATsuby
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to stock is a project too

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I thought of this on the way up to the cities back home. The starting issue seems a lot like not having a cam reference angle. It never starts on the first try. I crank for 3-4 seconds, stop. Do it again and it will start but its not a smooth start up. The only time I can remember something similar is when a cam sensor was not plugged in. Naturally now I can't check it till next time.

I have a check engine light on but I don't have a cable to pull the code or AP so I will need to get one or the other if I want to pull them. I'm hoping its something easy like the cam sensor is unplugged.

Ben
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Old 12-27-2011, 09:37 AM   #134
omahasubaru
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Congrats on the progress Ben!! Good work!
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Old 12-27-2011, 11:01 AM   #135
PHATsuby
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Quote:
Originally Posted by omahasubaru View Post
Congrats on the progress Ben!! Good work!
Thanks Jon,

I'll feel better once it's starting up correctly but it's coming along, a lot slower than I want, per usual lol.

Ben
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Old 12-29-2011, 04:09 PM   #136
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Excellent Ben! Good to see this coming together. I know it's been a work-in-progress for a while so good to see some major project milestones checked-off the project list. Keep up the great work.
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Old 01-05-2012, 11:21 AM   #137
STIdarkside
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Any updates? Keep up the great work Ben.
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Old 01-05-2012, 02:08 PM   #138
PDAWG
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It's alive, IT'S ALIVE!!!!
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Old 01-08-2012, 08:29 PM   #139
rougeben83
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:happybanana:
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Old 01-08-2012, 11:35 PM   #140
PHATsuby
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to stock is a project too

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No updates unfortunately, was down at home for a total of about 4 hours today for an 80th birthday party so nothing done on the car. I am planning to go down next weekend to troubleshoot and hopefully make some progress.

Not sure if I mentioned this but there was a bad balljoint on my driver's side. The thread is all screwed up so I can't thread the castle nut on it. I also can't put a die on it because the balljoint just spins. Naturally that is the side with the stripped bolt holding in the ball joint... I could source a used knuckle but I hate to get something with 100k+ miles vs my 40k miles on the wheel bearings, although I may just have to.

On a related note I ordered the keyless entry module and there is apparently an "integrated unit" for the 2004 baja but I am not quite sure what it does as it is neither canbus nor an immobilizer equipped car. I figure I probably need it so I ordered one. Hopefully it does some good being there.

I have gotten a couple ideas on the starting issue to test next time I am down so hopefully I can figure that out.

Ben
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Old 01-14-2012, 09:21 PM   #141
PHATsuby
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to stock is a project too

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Note to future swappers, your car starts much better when your cam sensors are plugged in.

So basically it was exactly what I thought, no cam reference. I looked at the driver's side cam sensor saw it was not plugged in. Plugged it in thinking that was it. It started up but not as well as it should. So I went and checked the passenger side, found that was unplugged as well. Plugged that one in and now it starts up perfectly. I'm going to go try and start it again here after letting it sit for about an hour just to make sure it isn't a fluke.

Needless to say I'm pretty pumped, I also was able to swap out the messed up balljoint for a new one(luckily had one on the 2009 STi knuckle I had lol) so I can finalize bolting the control arms and such together. It's getting close! I'm seriously hoping to have it finished after one more weekend assuming no issues with my steering rack binding or anything once it's on the ground.

I need to finalize some of the wiring now by soldering it together. I actually ordered a stock gauge cluster to put in for now just so I can get the car on the road and not mess with the STi one. Once I'm done with CFA in June I'll wire it in and do some other final aesthetic things. I'll likely look to install a DCCD Pro at the same time.

Hoping to make some more progress tonight/tomorrow to get things closer to finished for the next weekend I can come down and hopefully put it on the ground and go for a drive!

Ben
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Old 01-14-2012, 10:23 PM   #142
STIdarkside
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Congrats Ben. Glad to hear you figured out the starting issues. Please snap some pics of it once its on the ground and you take it for its first spin.

Well done man!
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Old 01-15-2012, 11:28 PM   #143
PHATsuby
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Well, made some more progress today. I got the steering hooked up finally but I need to adjust it as it visually looked straight but when I turned the steering wheel it turns slightly less to the left.

I soldered the wiper motor so that is done, I should be able to install the wipers and hood next time pretty easily.

The one thing that concerned me was that the coolant gauge went up to the top after running for 5 mins. I assume(hope) it's just an air bubble in the system. I topped it off then started it again and revved the motor a few times to help circulate it.

I'm partially annoyed because I just realized the gauge cluster I ordered, the temp gauge will not work properly I don't think. I bought a 2003 legacy gauge cluster which has a 2 wire temp sensor and the baja/sti is a 3 wire.

I need to keep an eye on the front axles, I realized when I was bolting things together today that the front axles are likely a bit longer than stock and I used the BH aluminum control arms. If I get binding I guess I should have just gone with the GD Sti control arms...

I took a video of it running and revving but the mic on my digital camera is terrible, you don't get any of the bass and actual sound of how good it is.

I'm still decently confident I can put it on the ground and drive it the next weekend I am down but it may not be 100% finished up in terms of interior being put together.

Ben
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Old 01-16-2012, 12:09 PM   #144
RooTBeeRthe1st
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Awesome, sounds like your making good progress still. Hope to see it driving around next time.
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Old 01-22-2012, 09:06 AM   #145
PHATsuby
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to stock is a project too

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Well, got some more stuff done today. Slowly but slowly getting there...

This is why I hate working in the winter with no heated garage. Started at 0 degrees today, makes it very hard to want to work in those conditions.


Got the 2003 gauge cluster installed. It's amazing what chrome rings and black overlays does to the look, I like it. I have too much invested to ditch my other cluster but I'll definitely be fine leaving this for now.


Goodbye to car audio days. This rats nest has been in my trunk for years, finally got around to removing it so I can carry the STi spare and have a clean trunk.


Starting to look like a dash again, gives me some hope it may actually be driveable again some day.


If anyone was curious what it looks like with the carpet removed here you go. Totally bare. I kind of like it, it's very hardcore. I won't really be doing much racing so I don't care as much about weight. That's what my next project is for.


It's a new car! Nice new carpet. No more drinking or eating in my car lol.


Oh, hello there.



I wasted a ton of time trying to find where the cruise control module plugs in only to finally discover there is none. All my diagrams and even opposed forces shows one for the turbo(or rather my diagrams must not specify non turbo). The cruise is all controlled by the ecu which is what I thought but found multiple places saying that the part number for my legacy CC module worked on the baja(one place said turbo as well).

I still need to solder wires tomorrow, correct the steering and bleed the brakes/clutch. The big hold up is the stupid bulkhead harness in the fender area I feel like it is not sitting in there properly and I can move it to where it needs to go to have the clips snap in place. I don't want to work it too much because I already have the fuse box in place so I'd assume everything else should be close but I guess not.

I'd really like to take it for a test drive but that may be a lot to ask and likely take all day. We'll see what happens.

Ben
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Old 01-22-2012, 10:16 AM   #146
RooTBeeRthe1st
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It's looking good, and holy crap that's a lot of stereo wires!!! lol
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Old 01-22-2012, 11:43 AM   #147
Patrick Olsen
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Is that OEM carpet, or did you find someone that makes good aftermarket stuff? I think I might want to replace mine at some point, but hadn't found anyone that makes aftermarket Legacy carpets (only Imprezas).
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Old 01-22-2012, 12:32 PM   #148
PHATsuby
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Quote:
Originally Posted by Patrick Olsen View Post
Is that OEM carpet, or did you find someone that makes good aftermarket stuff? I think I might want to replace mine at some point, but hadn't found anyone that makes aftermarket Legacy carpets (only Imprezas).
Yes it's OEM carpet, I just ordered it from the dealer with the part number off of opposedforces.com. It was only like $120 which isn't too bad I don't think.

Ben
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Old 01-22-2012, 11:17 PM   #149
PHATsuby
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Well, naturally still not driving the car. Made small progress but I'm really getting held up by the bulkhead harness in the fender. I don't see how it's supposed to even fit, all other parts of the harness should be in correct locations but it just seems like it hangs down way too far. That is holding up my installation of the wheel to correct the steering rack.

I did install the drivers caliper and hooked up the front brakes and installed the stainless steel lines. I am going to try one of those speed bleeders I think to see how that goes.

I soldered a majority of the wires inside the car, besides the airbag plug. The only thing left to solder besides that are the reverse/neutral position switches and the front ABS wires.

I installed the driver's side seat but realized I need to swap bases which is annoying because I thought they would be bolt in. They sit higher than stock I assume for the lower average japanese height. So I have to swap those next time, hopefully it's fairly straight forward.

I need to figure out if I need an illumination control module because the legacy one does not work(no plug I can find for it) and when I go to turn my headlights on the cluster does not light up, it actually has the LCD panels lit up with the lights "off" but when I turn the stalk to "on" they turn off and the cluster does not light up. I believe I do need an illumination module I just have to talk to the dealer to see what the part number is.

It's so close but so annoying that it seemingly has been for so long. On the bright side it was warmer today and my propane heater is still on it's first fill, but will need more next time down.

Ben
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Old 01-25-2012, 12:59 PM   #150
TylerHartman
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Epic Build man, Keep up the great work and Good luck!
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