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Old 08-15-2003, 02:17 PM   #1
stimpy
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Default It's beginning...

Lookit what I've got sitting in my basement:



My motor is currently sitting in my living room until I get the bolts to put it on the engine stand and find another three people to help carry it down the stairs

-Jon
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Old 08-15-2003, 03:19 PM   #2
totoherbs
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.... 122 IggPoints
Work... ahhh... so tired.

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dude... how many axles do you have ???
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Old 08-15-2003, 03:19 PM   #3
garface
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Oh c'mon, two people can carry the motor easy. What are you doing anyway? STi swap? You're about to have a lot of "fun".
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Old 08-15-2003, 03:46 PM   #4
stimpy
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I've got 8 axles in my basement, and another 4 installed on my L.

2 MY03 WRX sedan front axles (man are they thick)
2 MY00 Legacy front axles
2 MY01 2.5RS rear LSD axles
1 MY00 Legacy Outback rear non-LSD axle
1 MY99 Forester rear non-LSD axle
2 MY96 Impreza front axles (in use)
2 MY96 Impreza rear non-LSD axles (in use)

For the record, I didn't ask for the WRX, Legacy Outback, or Forester axles

The clump of wiring is for a MY03 USDM swap into a MY96 Impreza L.

-Jon
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Old 08-16-2003, 01:37 AM   #5
stimpy
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We got the engine downstairs. Did it with only two guys.

Here is the mess that is my storage room:



Turbo and manifolds have been removed and oil was drained. I should have pictures of the oil pan tomorrow to see what kind of damage, if any, has occured during shipment.

-Jon
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Old 08-17-2003, 05:17 PM   #6
stimpy
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Timing marks all line up properly and the engine will spin without hanging or anything. Plugs look a little more brown than golden, but they appear to be in decent shape.

I found that someone jacked my timing belt cover though. I'm not sure what happenend, but two of the nuts have been removed from the rear driver's side timing belt cover.



I also picked through the wiring diagrams and hooked up my gauge cluster. Looks like the engine didn't have 7k miles on it. It had 8k miles



Oh yeah, and black tape leaves one hell of a mess on your hands and on the wires. I've already come across a couple ghetto splices right at the gauge cluster.

-Jon
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Old 08-17-2003, 11:29 PM   #7
Jaxx
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8000 miles and they left the gas tank empty too

hmm i was under the impression that the cam gears were plastic on the ej205
mine (which sat in a japan junkyard, a crate on a ship and a seattle yard had no rust on them ...

ghetto spilces like turbo timer or some monkey in the factory
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Old 08-18-2003, 02:07 AM   #8
stimpy
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Gastank was actually at 1/3 full. When I hooked up power to the onboad CPU, it read no signal from the fuel level sensor and dropped the reading to empty. If you look closely, you can see the fuel light is on as well as the airbag light.

All four cam gears are metal, albeit I have three different types of cam gears I've heard that the STi has plastic cam gears, but not the WRX.

Ghetto splices like some monkey from the factory did it.

This motor came from Chicago and I think it lived through a NE winter. On top of that, I think it got kind of rained on while in Chicago.

-Jon
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Old 08-18-2003, 08:01 PM   #9
spiralsmurf
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jon, how much of that wiring do you think is gonna be left after you're done? seems like at least half of it is unneeded.
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Old 08-18-2003, 08:15 PM   #10
stimpy
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I would imagine most will not be needed. However, I haven't begun to pick through the main harness to determine that yet. Keeping in mind that all that we need out of the harness are those wires that pertain to the engine itself. Other things like lights, airbags, etc will be retained through the existing harness.

-Jon
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Old 08-18-2003, 08:50 PM   #11
serious
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Do you have a clothes line out back too?! Just kidding. The wrx engine i have in my basement (although a garage!) has 1 metal timming gear and the rest are cheesy a$$ plastic.
Good luck with that swap.
B
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Old 08-18-2003, 09:03 PM   #12
spiralsmurf
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whats the white plastic box in the picture of all the wiring?
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Old 08-18-2003, 09:06 PM   #13
serious
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The one with the black tape around it? Subaru does this for some reason for some of the wires under the dash. Probably to protect it.
Brent
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Old 08-18-2003, 11:07 PM   #14
Scooby South
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Quote:
Originally posted by spiralsmurf
whats the white plastic box in the picture of all the wiring?
I will take this one.......The WRX harness goes thru the fenderwell so the plastic is there for protection...

Bill
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Old 08-19-2003, 02:59 PM   #15
Puckaveli
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actually all newer bulkhead harnesses have the plastic cover on them and it used for mounting purposes as you can see the to mounting holes in the top. At leas that is the case with a 2000 RS harness.

Be glad you don't have plastic cam gears they suck and the UK guys despise them.
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Old 08-19-2003, 03:20 PM   #16
stimpy
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Actually, I inspected everything closer and I have 3 plastic gears too. Each gear is completely different from the other.

-Jon
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Old 08-20-2003, 12:42 PM   #17
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Got some work done over the past couple nights. I inspected the oil pan and it is slightly bent, but probably not enough to be of concern. It is only $40 for a new one so I'm currently deciding if I want to pay for another one and do the work to replace it.



I also have a bent power steering pulley. Theoretically, there is a single nut that keeps the pulley attached to the power steering pump shaft, however after hitting it with PB Blaster, an impact driver, and finally a breaker bar, the hex nut finally stripped. I was told that would probably happen so I pulled the entire shaft assembly out of the pump and I'll be getting a new one.




I didn't have the energy to start a new project after fighting that stupid retaining clip for an hour so I will be getting into the wiring in the next couple days.

-Jon
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Old 08-20-2003, 01:07 PM   #18
Wagon Joe
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Let me know if you need a hand sometime over the next few weeks. I owe you after your help on my uppipe install.

- Joe
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Old 08-20-2003, 06:06 PM   #19
Jaxx
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bummer i just sold a gda power steering pump
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Old 08-21-2003, 01:26 AM   #20
stimpy
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I have some progress, but nothing nearly as cool as Scooby South's.

I spent about an hour combining all my techinfo wiring docs into one big file so searching through the wiring diagrams is now quite easy. If I need to find all instances of connector "i2" I can just scroll through the document looking for the connector or just do a file search. It's all bookmarked and whatnot so I can jump around quickly and painlessly.

I spent about two hours actually labelling some connectors tonight. Man, that is some tedious stuff. I did manage to get almost all of the wires on two of the bulkhead connectors labelled though, so, at the very least, I've got almost everything known for the guage cluster and also a bunch of the opposite ends of the bulkhead wiring harnesses. Atleast one wire is not explicitly mentioned anywhere in the wiring diagrams so it looks like I'll have to trace the wire off the bulkhead wiring harness on the other end. There are a couple things that made no logical sense on how to describe it. There were also a couple wires that appeared to be ambigious but were clarified in another diagram.

Here is what my cluster harness looks like after removing most of the tape and labelling:



For my own curiosity, I removed my fuel pump today to see what I was going to have to deal with. I can't find my pictures of my RS fuel pump, but it looks like I have the stubby fuel pump from the earlier models. Worth noting is that I do not have the fuel temperature sensor or the fuel tank pressure sensor equipped on my car. The MY03 WRX ECU expects those signals so I'm not sure what I will do.



-Jon

Last edited by stimpy; 08-21-2003 at 01:31 AM.
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Old 08-21-2003, 06:35 AM   #21
spiralsmurf
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get a wrx fp and controller and wire it in
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Old 08-21-2003, 03:25 PM   #22
stimpy
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Quote:
Originally posted by spiralsmurf
get a wrx fp and controller and wire it in
I'm not sure how that resolves anything. The parts that I don't have are either external from the fuel tank (fuel tank pressure), or part of the fuel pickup assembly (fuel temperature sensor). Simply replacing the fuel pump with a WRX unit achieves the necessary fuel flow that I need (and it will be done) and wiring in the fuel pump controller just adds additional intelligence to the fuel pump relay (needed for the ECU).

As per the FSM
Quote:
Fuel Pump Control
Using the signal from the crankshaft position sensor, the ECM controls operation of the fuel pump by turning its relay ON or OFF. To improve safety, the fuel pump is stopped if the engine stalls with the ignition switch ON.
I haven't been able to hunt down the connector for the fuel pump controller to know what wires it takes. I'll see if I can do that tonight. I just casually looked through the diagrams but didn't see anything jump out at me.

I was originally quoted the entire fuel tank assembly for my conversion and I'm waiting back to hear about that.

-Jon
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Old 08-21-2003, 04:09 PM   #23
spiralsmurf
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jon, thats what i meant...you should replace it w/ the complete wrx fuel tank/pump assembly.
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Old 08-21-2003, 05:10 PM   #24
stimpy
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Oh, ok. That is what I'm hoping for. My engine source has said that the WRX tank will not physically fit due to a change in the rear seat structure underneath the car. He has been right about everything else thus far so we shall see. In my mind, even if I cannot actually fit the entire tank into the car (though Eby put his in) I would atleast have all the parts necessary to retrofit. What I don't get is why on earth did the EJ18 cars come equipped with all these parts but they were excluded from the EJ22 cars??

-Jon
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Old 08-21-2003, 07:02 PM   #25
spiralsmurf
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jon,

if you don't mind me asking, who is your engine supplier, how much did you pay for your stuff, and does he have more engines?
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