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Old 11-16-2014, 12:53 AM   #1
LucasBlack
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Default EZ36D H6-swapped 2006 Impreza 2.5i Build Thread

(**Too long, don't feel like reading -- go to Post #2**)
Hi Everyone! Welcome to my build thread for my beloved Impreza track car (we'll get to that in a bit). But first...

So, background:
I bought the car in September of 2012: a 2006 SGM Subaru Impreza 2.5i w/ a 5 speed. At that point, it looked like this.



It had, let's say, a ...few... things about it that I knew I wanted to change immediately ...and a few more items which weren't captured in this photo. That said, I felt that I got a pretty good deal on it, and at the time, it was supposed to just be a nice daily driver, and it came with thorough service history records.

I took my first swing at getting the car more to my liking: Tokico Blues, RCE Regular Guy springs, STi BBS wheels w/ BFG g-force sports, hood scoop delete, and some other miscellaneous items. By the end of November 2012, it looked like this:



This setup was great for the day-to-day; it was fun enough for daily driving and very comfortable. I continued to do a handful of other upgrades. The most significant being a PPG RWD Conversion Spool and a Cusco RS 1.5 Way Rear LSD. The community may shun me, but I've just never been a big fan of AWD (*hides*), and especially with the low HP rating, I much preferred having that concentrated to only the rear two wheels.

Things stayed this way until June'ish 2013, then this happened:



Long story, short (too late): I felt that my setup at the time was terribly lacking in the handling department -- I couldn't believe how out of sorts the car felt once in a place where I could actually push the car hard. Thus, the focus for the car intensified, and more mods soon cameth.



Feal Coilovers
Recaro bucket seat
Caster-adding STi aluminum lower control arms
Whiteline Offset Front LCA Rear Bushings
Roll center adjusting ball joints and tie rods
Work 17"x9" Cr-Kai wheels w/ Hankook R-S3's
All this (and a few other tidbits) led to more of this:



Which, as things go, led to this:



My first trackday was at Thunderhill in Willows, CA in November of 2013. I was officially hooked from that point forward, and the Impreza's purpose had been solidified. And this just about brings us to the pivotal point in the Impreza's transformation.
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Last edited by LucasBlack; 11-16-2014 at 04:33 AM.
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Old 11-16-2014, 12:54 AM   #2
LucasBlack
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Soooooo, after November, I immediately signed up for another trackday in December. At this trackday, I learned that the Wilwood Dynalite 4-piston "BBK" w/ ~12.2" dia. x 0.80" thick rotors running their BP-10 brake pads are in no way, shape, or form meant for track duty. Nothing catastrophic occurred, but after the second session in the morning, I was 1mm or so away from the backing plates. I had started the day on pads with at least half their thickness left. So, yeah, not so good... At this point, I upgraded to '05 Legacy GT calipers: running Carbotech XP8 pads on DBA rotors.



With pad and rotor sizes nearly equivocal to an STi Brembo setup, I was good to go again! This setup kept me going in January through March -- during which I had 6 more trackdays. One weekend of which was spent at Infineon (Sears Point, Sonoma Raceway, all of the above), which is a great, technical track (and beautifully set into the hills)...



TL;DR
All in all, I spent six months building up my Impreza from a decent daily driver to a pretty competent track car. Only thing was, at the end of that six months, I had become pretty comfortable with the available power and had decided upon upgrading. I wanted to keep it naturally aspirated, so the only logical choice...



...was a 256hp 3.6L Subaru EZ H6.
EJ253 out of my '06 Impreza on the left; EZ36D out of an '08 Tribeca (w/ ~43k miles) on the right.



Bolts right up to the 5-speed! And in 10 minutes, you can get it in the engine bay.


Here is a shot from above.



Once in, then the real job of getting it working took place. One of the items that required some fabricating were the headers. OEM EZ36D headers contact the U-shaped subframe on the Impreza. It's difficult to tell in the next photo, but we were able to cut the headers in multiple spots around the catalytic converters, rotate certain pipe sections to get the bends we wanted to clear the subframe, then weld it all back together.



What I would consider to be the unsexiest part of the whole thing was getting the stand-alone ECU wired in. While for the most part, things went smoothly by paying close attention to wiring diagrams for both the car and the ECU and then playing wire matchmaker, there was a horde of issues and nuances that the technician handling it all filled me in on throughout the whole process. I think those that actually enjoy wiring are magicians or psychos (or a little of both). Below is a shot of things at the beginning (see how nice and neat it all still is?)



Now:
That more or less brings us to today! (er, yesterday...) After some ECU setup troubleshooting and some initial test cranks after making sure there was fluid where fluid needed to be, the engine sang again for the first time in its new body!


Tidying up of the wiring, finalizing a couple brackets/hangers, and finalizing of the tune are still necessary, but it runs, idles, has driven its first 50 feet, and I can't wait to get it back out on track!!

Thanks go out to the guys at Lifted, Inc. in Fremont, CA for handling the swap -- couldn't have done it without them!

Thanks everyone for checking out my ride!

Last edited by LucasBlack; 12-18-2014 at 07:22 PM.
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Old 11-16-2014, 12:55 AM   #3
LucasBlack
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Bonus shots!



Recaro Bucket; delrin shift knob



STi Brembos to complement the new motor



Installed a 4.44 FD from an auto-trans Forester; marks on LSD carrier are from when it was initially installed (by a different shop).



My 4-door sedan now seats ...2.



From my first trackday last November. Looking forward to the ones to come.

Last edited by LucasBlack; 11-16-2014 at 04:15 AM.
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Old 11-16-2014, 01:26 AM   #4
tikbhoy
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When did the swap happen?
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Old 11-16-2014, 04:20 AM   #5
LucasBlack
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Post #2 fills in the rest of the story up 'til now. The swap technically started in April, but I didn't finalize an ECU choice until the end of June or so, and the engine ran just yesterday.

This car became a sort of shop project car, and with the fact that there isn't much of a precedent set for this swap, it was a lot of figuring it out as we went.
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Old 11-16-2014, 11:40 AM   #6
RM_2
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2001 Legacy L WGM

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That is an awesome swap! I look forward to more pictures of this build.
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Old 11-16-2014, 11:47 AM   #7
coleman em1
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very nice, more pictures!!!
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Old 11-16-2014, 04:22 PM   #8
SnatchedHatch
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This is ungodly! Holy .... I implore you to finish! That will be sickest winter machine on the planet.
Our 3.6 Outback pulls 100m drifts all winter long, but you must be doing it along with boost for drag or just to have the first EZ3.6 swap?

Edit: Missed that bit, kudos on you for the N/A RWD setup, maybe a S/C is in the works for the future?

Good luck, finally someone had the gall. It's nice to know it can bolt up to the 5 speed, update on if it can actually run it long term when you can!

Last edited by SnatchedHatch; 11-16-2014 at 06:09 PM.
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Old 11-16-2014, 06:12 PM   #9
SnatchedHatch
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Noticed this guy from 2011, when viewing your test fire vid. Maybe he can give tips since he seems to have already completed the 3.6 swap.

EZ36 Liberty Rally project - First Start up:

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Old 11-16-2014, 07:12 PM   #10
LucasBlack
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Quote:
Originally Posted by SnatchedHatch View Post
Noticed this guy from 2011, when viewing your test fire vid. Maybe he can give tips since he seems to have already completed the 3.6 swap.

Sent from my Nexus 5 using NASIOC mobile app
Funny that you bring that guy up; when I started this project, I was in contact with the tech that did his ECU install and base map.
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Old 11-16-2014, 11:21 PM   #11
LucasBlack
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Quote:
Originally Posted by SnatchedHatch View Post
This is ungodly! Holy .... I implore you to finish! That will be sickest winter machine on the planet.
Our 3.6 Outback pulls 100m drifts all winter long, but you must be doing it along with boost for drag or just to have the first EZ3.6 swap?

Edit: Missed that bit, kudos on you for the N/A RWD setup, maybe a S/C is in the works for the future?

Good luck, finally someone had the gall. It's nice to know it can bolt up to the 5 speed, update on if it can actually run it long term when you can!
Planning on keeping it NA for the foreseeable future, but who knows, things could change.
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Old 11-16-2014, 11:54 PM   #12
Jive Turkey
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gonna do any tuning upgrades to current motor?

you should look into a better coilover once all back on the road, while your under there do some bushings and other inserts!
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Old 11-17-2014, 01:45 AM   #13
LucasBlack
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There isn't much at all out on the market as far as simple engine upgrades go for the EZ36 (to my knowledge). The main thing I'm looking forward to is seeing what horsepower it will put down with less drivetrain loss, and being optimally tuned to 91 octane compared to its factory tune on 87 octane.

The Feal coilovers (I'm currently running 9kg/mm front springs and 6kg/mm rears) I think are a very competent setup, and still capable of being very road friendly. There is "room to grow" with regard to getting more track-dedicated damper tuning and uprated springs (which then I'd likely just send them back to be rebuilt to a higher spec), but I'll see how things go when I get back on track.

In reference to your point about bushings and such forth, I'll go ahead and provide my full mod list here:

Scoob Mod List:

Powertrain:
EZ36 H6 engine (43,112 miles at time of install; ’08 Tribeca donor vehicle)
Vi-Pec i88 Standalone ECU
STi Full Catback Exhaust
Mishimoto Engine Oil Cooler
2002 Outback H6 Radiator / SPAL 13” Low Profile Puller Fan
GC8 JDM STi MAF Housing / 2007 Outback H6 MAF
Walbro 255Lph Fuel Pump

Suspension/Handling:
Feal 441 Coilovers [9kg/mm: front (8kg/mm spares), 6kg/mm: rear]
Whiteline 24mm Adjustable Front Anti-Roll Bar
Perrin Spherical Bearing Endlinks
OEM 2007 STi (20mm) Rear Anti-Roll Bar
OEM STi Rear Endlinks
Front Camber Bolts (1 pair)
Whiteline Adjustable Lateral Links
Rear Camber Bolts (1 pair)
JDM Spec C Front LCAs (ver. 8: caster adding)
Whiteline Offset Front LCA Rear Caster Bushings
SuperPro Roll Center Adjusting Ball Joints / Tie Rod Ends
2006 STi Steering Column Solid U-Joint

Chassis:
OEM EZ30D Motor Mounts
Kartboy Pitch Stop
Kartboy "Botox" Rear Subframe Lock Bolts
Whiteline 02-07 NA steering rack bushings
Subaru STi Group N Transmission Mount
TiC Transmission Crossmember Bushings
Kartboy Rear Diff Mount Bushings (Comfort)
Kartboy Rear Diff Outrigger Bushings (Comfort)
JDM Lightweight Front Bumper Beam
Spec C Titanium Strut Tower Bar

Wheels:
Enkei Raijin 18”x8.5” +45 offset w/ 255/35/18 Hankook R-S3 (w/ hubcentric rings)
Past:
'04 STi BBS Forged 17"x7.5" +53 offset w/ 225/45/17 BFG g-force sport 2
Work Emotion CR Kai 17"x9" +38 offset w/ 245/40/17 Hankook R-S3 (w/ Motorsport Tech aluminum hubcentric rings)

Drivetrain:
PPG (Pfitzner Performance Gearboxes) RWD Conversion Spool
Cusco Type RS 1.5 Way Clutch-Type LSD
4.44 Ratio Final Drive Ring and Pinion Gear (Auto-trans Forester FD)
Exedy Stage 1 Clutch (WRX - 15804)
Exedy Lightweight Flywheel (FF502)
Perrin R160 Rear Diff Cover
Perrin Adjustable Short Shifter
Perrin Shifter Bushings (front and rear)

Brakes:
STi Brembo 4-pot front brakes; Wilwood SS Brake Lines
WRX rear 2-pots w/ kartboy adaptor brackets; StopTech SS Rear Brake Lines
'04 STi Brake Master Cylinder
TiC Master Cylinder Brace
996 GT3 Brake Cooling Guides (modified)
StopTech Titanium Brake Pad Backing Plates
TiC HTS Hub Bearing Titanium Shields

Other:
Odyssey Lightweight Battery (PC680)
STi OEM Roof Vane
‘Monster’ Carbon Fiber trunk lid (7 lbs.)
WRX Hood: scoop replaced w/ KSTech louvered vent plate and mesh cover

Interior:
Schroth 4-Point Quick-Fit Pro Harness
Recaro Pro Racer SPG XL Seat
Recaro Side Mounts
Planted Technology Seat Base
Delrin shift knob

Last edited by LucasBlack; 11-17-2014 at 02:00 AM.
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Old 11-17-2014, 05:46 PM   #14
JourdanWithaU
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Which AutoX groups do you run with? I also assume that you'll continue to AutoX? Signed up for any upcoming Track Days?

(I kinda want to see this car)
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Old 11-18-2014, 04:00 AM   #15
LucasBlack
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Quote:
Originally Posted by JourdanWithaU View Post
Which AutoX groups do you run with? I also assume that you'll continue to AutoX? Signed up for any upcoming Track Days?

(I kinda want to see this car)
The AutoX group I ran with last year was Norcal UFO (United 510 Owners), but they're no longer running events (down in Seaside), and I just haven't been doing AutoX's either since I started doing trackdays.

My next event is Dec. 1st at Thunderhill w/ NCRC.
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Old 11-18-2014, 01:13 PM   #16
JourdanWithaU
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Interesting. I usually run with SFR and occasionally with AAS. I signed up for my first track day at Thunderhill with GDS on Dec 21st.
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Old 11-18-2014, 02:20 PM   #17
LucasBlack
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Interesting. I usually run with SFR and occasionally with AAS. I signed up for my first track day at Thunderhill with GDS on Dec 21st.

Very cool! Do they offer instructors at all? Which configuration are they doing on that day?
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Old 11-18-2014, 03:39 PM   #18
JourdanWithaU
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Quote:
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Very cool! Do they offer instructors at all? Which configuration are they doing on that day?
I believe they will have instructors. They will have a lead and follow sessions. My understanding is that they are a very beginner friendly group.

They got the full 5 mile course that day.

http://www.gripdriftskid.com/
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Old 11-19-2014, 03:19 AM   #19
LucasBlack
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Quote:
Originally Posted by JourdanWithaU View Post
I believe they will have instructors. They will have a lead and follow sessions. My understanding is that they are a very beginner friendly group.

They got the full 5 mile course that day.

http://www.gripdriftskid.com/
If they do a lead/follow session, that would be great (especially for the 5-mile track). That's a lot to learn all at once, so definitely take your time building up speed. Hope it goes well for you!
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Old 11-19-2014, 10:36 AM   #20
JarHarms
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02 Forester S

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Cool. How was the radiator/fan fitment? Did those parts bolt in pretty easily? It always seemed to me that was a large part of the install challenge aside from wiring. Good job.
SGM is the best color too.
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Old 11-19-2014, 11:39 AM   #21
Patrick Olsen
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Very cool swap/build, I'm definitely interested to hear your driving impressions once you get the car back out on track. Your train of thought is much the same as mine - I like the N/A power delivery, I just want more of it.

I'm curious to see how the cooling system works. Due to different space restrictions I've had to contend with on my '97 Legacy, I wasn't able to use an EZ30 radiator, so I'm still using my stock radiator. The core size is essentially the same, but my stock radiator uses side tanks rather than top/bottom tanks; the top/bottom tanks make the EZ30 radiator too tall to fit in my car. I've got the two upper hoses combining into a header I had welded together, and then that feeds the single upper inlet on the radiator. Hopefully that configuration doesn't compromise flow too much, but we'll see. For fans, I also went SPAL, but I've got 2 - part numbers 30101504 and 30101507 (12" and 13" medium profile):




And, for your future upgrades , howzabout these headers from Raptor. Obviously shipping would be a little steep, but under $400 (Australian) for stainless headers is pretty nice. With that said, they're not an ideal design, as they're intended to fit with the stock cats (cut the stock pipes, weld on flanges). Some folks have made their own long tube headers, which would be even mo' better.
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Old 11-19-2014, 01:27 PM   #22
LucasBlack
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Quote:
Originally Posted by Patrick Olsen View Post
Very cool swap/build, I'm definitely interested to hear your driving impressions once you get the car back out on track. Your train of thought is much the same as mine - I like the N/A power delivery, I just want more of it.

I'm curious to see how the cooling system works. Due to different space restrictions I've had to contend with on my '97 Legacy, I wasn't able to use an EZ30 radiator, so I'm still using my stock radiator. The core size is essentially the same, but my stock radiator uses side tanks rather than top/bottom tanks; the top/bottom tanks make the EZ30 radiator too tall to fit in my car. I've got the two upper hoses combining into a header I had welded together, and then that feeds the single upper inlet on the radiator. Hopefully that configuration doesn't compromise flow too much, but we'll see. For fans, I also went SPAL, but I've got 2 - part numbers 30101504 and 30101507 (12" and 13" medium profile):




And, for your future upgrades , howzabout these headers from Raptor. Obviously shipping would be a little steep, but under $400 (Australian) for stainless headers is pretty nice. With that said, they're not an ideal design, as they're intended to fit with the stock cats (cut the stock pipes, weld on flanges). Some folks have made their own long tube headers, which would be even mo' better.

Pat, thanks for chiming in here with your (as usual) detailed responses; I've really enjoyed following your progress on the H6 Resource thread.

Indeed, my chassis (JarHarms) allows for a little more breathing room/space up front for the radiator and fans, but, like Pat, I had to switch to SPAL slim-line fans. I'm currently only running one 13" fan (though I may have enough room to upgrade to a slightly higher cfm fan in this location) , as the EZ30 radiator in an OEM fitment doesn't allow enough room to mount the 12" slim-line fan on the passenger side as the engine timing cover comes into contact with it. What I believe I do have space for though is to put a pusher fan on the passenger side between the radiator and where my oil cooler is mounted -- a slim-line looks to have enough room here (ala Mitsubishi Evo 8 w/ one pull and one push fan).

As for those headers, they do look pretty nice and would be a welcome improvement over the OEM setup -- maybe next year.

Thanks again Pat and Jar for the positive remarks!
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Old 11-25-2014, 02:26 PM   #23
Patrick Olsen
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QuickSilver Metallic

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What, if anything, have you done with the AVCS tuning? Does the Vipec already have AVCS maps in it, or are the cams just left in their "default" position unless the user chooses to activate that function?
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Old 11-26-2014, 06:37 AM   #24
LucasBlack
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Quote:
Originally Posted by Patrick Olsen View Post
What, if anything, have you done with the AVCS tuning? Does the Vipec already have AVCS maps in it, or are the cams just left in their "default" position unless the user chooses to activate that function?
Pat, as of now, nothing.
Vi-Pec, as far as I am aware, has/had no base maps for the EZ36D -- it just had the software set up capable to run the engine.
As of right now, I have a tune that is street safe but not yet optimized. Though, everything is wired up so that for future tuning endeavors, we will be able to take advantage of the variable cam timing.

For the immediate future, I've concentrating on getting a littly tidying up done: its first trackday (in its current form) is in 5 days.
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Old 12-02-2014, 08:11 PM   #25
Patrick Olsen
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Track event update ... go!
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