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Old 03-12-2011, 03:23 AM   #1
rallyjiggz
Scooby Newbie
 
Member#: 81059
Join Date: Feb 2005
Chapter/Region: VIC
Location: Victoria, BC
Vehicle:
2004 2.5TS-T (soon!)
Platinum Silver Metallic

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I'm writing out the questions to the little things I'm expecting to come across. Planning stages only, so far.

The general details: MY06 EJ257 short block OEM STi crank, pistons and rods, ACL bearings,ARP studs, mated to EJ251 heads, turbo'd using IHI VF30, 800cc fuel injectors, 255LPH fuel pump, STi intercooler FMIC with the RS/scoopless hood, standalone Hydra engine management AEM EMS, routed oil lines for turbo, WRX front engine crossmember, aftermarket catted dump pipes and headers (must pass BC AirCare next year), ACT SB2-HDSS clutch on RS transmission, 04 STi catback.
The short-term (one year) goal is to get the car on the road running mild, efficient boost across the entire power band. I'd like the car to run "easy" (as easy as hybrids with aftermarket engine management can possibly go) for the first year, document not only the build but also the first 6-8 months in as much detail as possible and from there start building up for more aggressive tune, do head work (cams, valve springs, etc).
The car has 180,000km on the odometer and was my first car since 2004, which means it has (sadly) endured the many stupid things I thought were smart as a teenager, plus the occasional autocross between 2004-2006. Lots of wear and tear, been driven across the country many times and was used to teach 2 ex-girlfriends how to properly drive stick. Thankfully, the girlfriend for the last 4 years already knew how and manages quite well. But to make my point, I'm ready for a new wagon at this point in my life but I love this particular one (call it sentimental value), so she's getting a makeover. The cost of a downpayment on a new Subie will hopefully get me another 5-6 years of utility out of the car, and the upkeep on suspension, tires, etc. may likely amount to the $$$ I would spend on modifications to a new car, anyway.

The current vehicle: naturally aspirated 2004 2.5TS sportwagon with suspension and brake modifications.

The little questions nagging at me in the planning stage:

- turbo brackets, do I need these for the turbo to stay in place?


- intercooler mounts, can someone point out to me where these are and if I need to have them? D'oh, solved. Use eyes to look.

- control arm bushings, transmission bushings, other bushings in and around the engine bay - on a car with 175,000km and original bushings, which ones would be a good idea to get to and replace (since the car will be up on stands and gutted) Motor and transmission mounts, strut mounts. Possibly control arm bushings.

- MY06 short block: can I get away with my MY04 RS oil pan and pick up tube? Why is the OEM MY05 oil pick up more expensive than the OEM MY06? I've heard that the 06 pick ups are notorious for failing - is this common in other years as well? Is Killer B worth the +$400 for a pick up tube?

- Can I get away with MY04 RS water pump?

- Do I need WRX or STi oil cooler / heat exchanger?

- A tuning shop suggested using AEM's fuel/ignition control unit instead of the standalone EMS - anyone have $0.02 to spare?



I'm sure I'll have more mundane little questions as the next couple of weeks go by, and I hope you guys can shed some light on the little things. My build isn't scheduled for another few months but, like a diligent planner I'm making sure I can get as close as possible to a detailed, step-by-step documentation of the planning process, build process, and post-build performance/reliability.

I'm also going to try my best to find the answers to my questions but I may post here for posterity's sake so that others may find what they're looking for.
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Last edited by rallyjiggz; 03-15-2011 at 01:18 AM. Reason: had to rush out the house, left the thread half completed.
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Old 03-15-2011, 01:16 AM   #2
rallyjiggz
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Member#: 81059
Join Date: Feb 2005
Chapter/Region: VIC
Location: Victoria, BC
Vehicle:
2004 2.5TS-T (soon!)
Platinum Silver Metallic

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questions answered, new ones added.
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Old 03-18-2011, 03:42 PM   #3
99imprezd
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Member#: 198964
Join Date: Jan 2009
Chapter/Region: Tri-State
Location: south NJ
Vehicle:
2004 WRX wgn, built!
WRB

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Im doing a similar build to my '03 TS but much less involved.. Im in the process of having my donor block bored, I've got the crank & rods from an EJ257, goin with MAHLE 100mm Pistons.. taking it from there.. Still dont have the motor back from the machne shop but will be checking this page for updates!
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Old 03-20-2011, 04:43 AM   #4
rallyjiggz
Scooby Newbie
 
Member#: 81059
Join Date: Feb 2005
Chapter/Region: VIC
Location: Victoria, BC
Vehicle:
2004 2.5TS-T (soon!)
Platinum Silver Metallic

Default

Awesome, 99imprezd! Just finished cleaning up after taking the ej257 short block apart tonight. Took less than an hour, I was surprised. I'm sure putting it all back together will be a challenge to make up for how smoothly the disassembly went.

My donor (ie cheap) block had a spun #1 bearing and it looks like it scuffed the crankshaft up a bit, but I'm going to have the machine shop inspect all the parts when it goes in for cleaning. The plan was to use the stock pistons but with the possible bore that needs to happen I may need to go with custom pistons.

I've got Tuesday free and hopefully will get the block back by end of week, which should be around the time that the rebuild kit will be in. Once the block is back together I simply need to get the rest of the parts in (including a new Hydra unit) - once everything is at my door, it'll be time to bring on the surgery and get this hybrid on the road.
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Old 09-17-2014, 10:10 PM   #5
Busaru48
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Join Date: Jul 2014
Location: Colorado Springs, CO
Vehicle:
2004 2.5TS

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Is this thread dead? Im doing the same swap and im stuck on the coolant crossover pipe as the n/a bumps into the crank breather port on top. And theres a threaded hole in the block im going to plug that i dont what its for.
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