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Old 05-17-2004, 03:25 PM   #1
Structure828
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Default EJ20G swap DONE...step by step process!

Case Closed: Super Impreza RS Swap Project

Well nearly a full 6 months later, and my girlfriends Ford Escort with like 30k more miles on it, my 1999 Subaru Impreza Swap Project is finally complete.

What I did...
Noticed that my 2.5rs had a small knock in the engine and wanted to upgrade the motor. I wanted to do a swap that was very rare and able to produce a great amount of power. A car to build on to get into an easy 13 to 12 sec 1/4 mile or so, that would be a great daily driver. I went with a EJ20G 2.0t Motor from a 1991 Japanese Subaru Legacy RS with rear LSD. It's also a closed deck motor

Reasons for the choice...
Super Super RARE motor to swap or find in the states.

The bad ass Aluminum AWIC that came on the car STOCK which most WRX's and STI's end up switching or upgrading to if they can get it.

CLOSED DECK (BULLET PROOF) Motor *to handle daily HIGH BOOST lvls*

AWJUNKIES thought I would be "cool" LOL!

220hp like the US wrx but a better built motor (jspec/closed deck/better tranny/more aggressive ECU from factory)

What it cost me...
$10900.00 for a used 1999 Subaru Impreza 2.5rs with 44k miles
$ 420.00 to ship it to FL. Because there were 0 Impreza's for sale here....
$ 200.00 for a WRX crossmember
$ 750.00 for the install/wiring
$ 1100.00 for the motor
$ 256.00 to pay for the storage fees for someone to get the motor
$ 100.00 to pay a friend to drive it 110miles in his truck
$ 50.00 for a Skyline recirc valve because the factory re-circ valve was cracked
$ 200.00 for a Jspec TD04 turbo (VF8 was frozen from sitting too long)
$ 247.00 for basically THEE best chip I have EVER seen. You hear about chips on cars all the time but this is an easy 30-40hp REALISTIC gain. It does adjust boost though as well. Great investment.
$ 40.00 for some aftermarket bushings needed for the front swaybar.
$ 40.00 for some brand new NGK spark plugs.
$ 218.00 for Accel Pro Series 60k volt Coil Pakcs w/wires (old coils dead)
$ 400.00 for a custom made 3" exaust strait back from turbo w/downpipe.
$ 60.00 for the setup needed for a K/N air filter and filter itself.
$ 20.00 for various bolts/plates/things needed to mount coilpacks
$ 40.00 for various hoses needed and clamps and new belts
-----------------------------------------------------------------------------------------------

What I had to go through...
6 months without my normal daily driver
A girlfriend of 4 and 1/2 years going nuts for driving me everywhere.
$1k in Insurance money for nothing, that just made my record look better
Contradicting info on the MRT/NASIOC/LibertyRS boards with no strait answers
48 computer hours+ worth of research for diagrams
Weed out the 2.2liter and 2.0 n/a wiring diagrams from the REAL stuff.
Deal with a mechanic (SMACKSUBE) who never answered phone :P
6 bee-bee holes on side of car from Smacksube's lil bro's friend
Literally had nightmares of bad things happening to my car.
Wishing I was driving a 5speed and making believe in my GF's Escort.
Lots of small but very unexpected various things that were needed to get it going

What I got out of it....
A good friend and a new mechanic Solomon.
A ton of help from AWJUNKIES and Matt Monson.
A 300hp or so (yet to be dynoed) at the crank Impreza and around 13.3 1/4mile
Fun REAR LSD
A cool Air to Water intercooler.
A fun daily driver (currently a mid to low 13 second) car.
The relief of finally having the major part done.

The STEP BY STEP swap Process...
#1 Purchased what was thought was a 93' Legacy RS 2.0 turbo motor
#2 Found out it was a Liberty RS EJ20T motor (Legacy actually)
#3 Found out that Liberty/Legacy are the same damn thing...
#4 Found out that EJ20G and EJ20T are the samn damn thing too...
#5 Got info off of the internet
#6 Smacksube dropped in motor in 3 days
#7 Spoke with Titan Motorsports for wiring help
#8 Spoke with Subaru of Jacksonville for wiring help
#9 Spoke with AWJUNKIES for wiring help
#10 Spoke with moderators on the RSLiberty forums for wiring help...
#11 Smacksube tried wiring for about 5 months with the help...
#11 Got no where with the process
#12 Got my car flat-bedded to Orlando to "Solomon's house"
#13 We got the car turning over in under 48 hours
#14 We noticed the spark was weak so coils and plugs needed to be upgraded
#15 Ordered Accel coils/wires and NGK spark plugs
#16 Replaced some seals and degreased the engine bay a bit.
#18 Officially got the beast to ROAR to life with the OK code from ECU
#17 Bolted on a 3" exaust and K&N Airfilter...
#18 Put the VOS chip on the ECU

My next steps over the next few weeks......

#1 Get my car repainted due to the damage suffered from my first mechanic's little brother.

#2 Buying brand new tires, havent decided which ones yet, and leaving the factory 99' RS wheels on, but having them painted a deep charcoal color.

#3 Upgrading the entire brake system. Most likely Wallwood, we will see.

#4 Front Strut/Sway bars to go with the Energy Suspension bushings.

#5 Bring it down to the track


My reccomondation to anyone who wants to do a swap like this...

Make sure you know what you are getting into.
Keep around atleast 500-1000 extra bucks for unexpected costs.
Make sure you TRUST and KNOW your mechanic before starting.
*****(I dont know how much I can stress that.)
Be prepared to rent a car or bum rides for a while. Or have a 2nd car available.

If all went well, I think the swap would of taken about a month and 1/2 or so. With Murphy's Law hitting me hard, it ended up being about 6 months.
I should have everything done, setup, working and ready to go within the next week or so. If anyone can HOST pics for me I will try to EDIT this post and throw some of them up this week.
I know that JAXX wanted to see how we bolted the TD04 intake portion on...
Ect... and I can take pics of the wiring, and the final shots of motor in.
Also how we ran hosing to work with the 2.5rs Radiator for the AWIC.

This car truly did become a complete custom swap process. We had to build custom plates for the coil packs and were able to mount them on top of the wheel well areas in the engine bay. Along with custom making the piping for the intake manifold, and doing a custom setup for the TD04 turbo and a lot of other stuff. We also had to turn and custom fit the throttle cable. It ended up looking not bad at all. All the wiring has now basically been hid and we are doing the minor details. Like workin on the tach and a few minor cables. The chip will be installed this week, after everythn else is set too.

It was a huge relief to hear it fire to life, it sounds pretty beast like. I guess any car does when u hear it and its OPEN TURBO w/out exaust yet

TY EVERYONE for all the help
especially Matt Monson and AWJUNKIES. You guys went out of your way to help me out. Along with 22RS-RA and Karupt from the RSLiberty boards. The guys in Australia and NZ helped me out a TON. If there is anything I can do, being that we kinda pioneered the way, I will help. Just send me a PM TY again everyone.

Also...I endorse the VOS chip out of Australia. It will cost people in the US about $250.00 or so, give or take with transfer fees. I have seen "chips" on just about every make and model car, and never heard or saw anything with so much proven power. If you cant afford or dont have a need to goto a stand alone, this chip puts a realistic 35hp or so to the wheels. Dyno proven. Its incredible what a smart Aussie can do with a car with potential!
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Old 05-17-2004, 04:17 PM   #2
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Wow, see, to anyone considering doing a swap yourself, this is why a lot of us recommend the USDM swap.

Congrats on finally getting it running. I know how that feels, but probably not to the same extent since you had 6 months of anticipation.
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Old 05-17-2004, 04:36 PM   #3
Structure828
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LOL, I actually didnt believe it happened when it did. I thought my mechanic's neighboor fired up a high powered POWER WASHER or something. It was great

I kinda just sat there while he celebrated for a few moments
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Old 05-17-2004, 05:03 PM   #4
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thats sweet it all worked out.

one question is why are you upgrading the front sway bar? have you upgraded the rear?
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Old 05-17-2004, 05:14 PM   #5
Structure828
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I will be doing both, I should edit the post.

The front stuff was bein taken care of first because of the WRX crossmember. New stuff was needed. TY for pointing that out
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Old 05-17-2004, 06:07 PM   #6
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Was the $1100 just for the engine or complete drive train? The ej20g engines are a dime a dozen, I have seen them go for $300 on ebay. The air to water intercooler is the worse flowing subaru intercooler, there is a great write up that intercooler and others on autospeed.com You say that you used the 2.5l radiator for the TMIC?? Pics?? I would like to see a dyno before and after that chip, I dont believe in generic chips, a $15 boost controller will give you what that $$$ chip does.

But its great that it runs and you are happy with it. I would personally ditch that intercooler and get a wrx TMIC, unless you want a very sleeper look(no scoop). What pump are you using for the intercooler?? Are you running the intercooler pump with the jdm ecu??
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Old 05-17-2004, 06:37 PM   #7
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Quote:
Originally posted by Scoobie Steve
Was the $1100 just for the engine or complete drive train? The ej20g engines are a dime a dozen, I have seen them go for $300 on ebay. The air to water intercooler is the worse flowing subaru intercooler, there is a great write up that intercooler and others on autospeed.com You say that you used the 2.5l radiator for the TMIC?? Pics?? I would like to see a dyno before and after that chip, I dont believe in generic chips, a $15 boost controller will give you what that $$$ chip does.

But its great that it runs and you are happy with it. I would personally ditch that intercooler and get a wrx TMIC, unless you want a very sleeper look(no scoop). What pump are you using for the intercooler?? Are you running the intercooler pump with the jdm ecu??
I think you are confused. It was the old air-air intercooler, the black one, that was the worst flowing intercooler. The air-water is a very good flowing intercooler.
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Old 05-17-2004, 06:52 PM   #8
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The AIR TO WATER intercooler I have is 1 of the best subaru made. New WRX's and STI's even switch to them if they arent doing a very expensive aftermarket upgrade.

Also...its a 2.5rs...I have a hoodscoop lol.

You can goto the RSLiberty forums to see dyno results. Believe me, mine will be up there. It is a big difference. I have seen chips for VW's, Audi's, Fords, Chevy's...just about everything, ranging up to $700 bucks or so, and never saw a difference as big as this. All the AUS and NZ people rave about it, we just dont get em thats all
It sets the boost from 12.9 to 16, its built around having an aftermarket airbox and 3" exaust. What it does for the fuel and ignition is incredible. There are people down there with near endless budgets who choose to keep the chip. They get results as good as any stand alone up to around 2500 bucks or so.
Im not boasting about it, because I am getting it, Im just telling you what the proven results are, and what I have seen before.
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Old 05-17-2004, 06:56 PM   #9
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Also, it was $1100 for the engine/tranny/ecu/harness/gauges...so basically a torn down front clip.
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Old 05-17-2004, 06:58 PM   #10
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Also keep in mind, this is the 1 with the VF8 turbo, that is very similar to the TD05 and VF12. THey used the same turbo on the RS-RA which was Subaru's oldschool record attempt car.

Not the automatic GT legacy or soemthing. LOL

But that turbo does need a basic rebuild that I will get to sometime this summer

Can anyone host pics?
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Old 05-17-2004, 07:15 PM   #11
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Quote:
Originally posted by Structure828
Also keep in mind, this is the 1 with the VF8 turbo, that is very similar to the TD05 and VF12. THey used the same turbo on the RS-RA which was Subaru's oldschool record attempt car.

Not the automatic GT legacy or soemthing. LOL
Is that a pot shot at my auto-EJ20G sitting in the garage with a VF-10 on it? You are welcome for any help I may have provided. But one last time I am going to say this: The VF-12 was on the RS-RA, and it is bigger than a VF-8, he11, it is even bigger than a TD05...

I am curious about this chip. It is for Legacy turbos only? I ask because I am using an JDM '94 WRX ECU to run my LEgacy GT engine. It is the same pinouts and wiring, minus two pins for the AWIC pump. But I am just going to hardwire it in and have it start pumping on engine start, so no big deal. But some links to info on the chip would be great. I imagine it plays with fuel maps and not just boost as has been suggested...
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Old 05-17-2004, 07:38 PM   #12
Structure828
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I believe the chip is for early WRX's and Legacy's...

I actually contacted the maker and he is going to get back to me, maybe to setup group buys for NASIOC or something. I will let you know for sure matt.

The head guy on the RSLiberty boards basically said that the VF8 and VF12 are next to the exact same thing. The TD05 is just a SLIGHT step up. We also found out there are 2 versions of the VF8. Some people compared the VF8 with the VF23 lol. There is an RBF and a RBH52...2 diff models. Either way, there is arguements everywhere over how big they are.

From smallest to largest its... .VF10 VF11 TD04 VF8 VF12 TD05 with the last 3 being very close, and the TD04 able to produce nearly as much power as the 8 and 12 with just a quicker spool and less top end
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Old 05-17-2004, 07:39 PM   #13
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I also saw 2 articles, 1 saying the RS-RA had a vf8, and 1 saying it had a vf12. My god, its like you would think its the same turbo, kinda like the Legacy and Liberty are the same thing. I found out WHY they had to call it Liberty too. They wanted to call it Legacy in AUS as well, but there was alreayd some car that had it in the name or osmethin

As for the chip... a bit more info I THINK he makes an 8bit for OLLLD stuff, and a 16bit for 91+ for all legacy's RS/GT/GX and some early WRX's...

Ive seen quotes like, my god I stuck it on my RS with a vf10 and it was like a ROCKET was stuck on the back of the car....

There is some info in the forums, just look it up. I will let you know when I get it too, so we will have some US results. He has diff chips with diff settings....depending on what turbo u are running ect...for the wastegate setting.
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Old 05-17-2004, 10:01 PM   #14
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Quote:
I think you are confused. It was the old air-air intercooler, the black one, that was the worst flowing intercooler. The air-water is a very good flowing intercooler
I think you are confused, here is the chart clearing showing the air-water intercooler sucking compared to the early "black" wrx unit. The core for the air-water intercooler is VERY small resulting in poor flow.

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Old 05-17-2004, 10:50 PM   #15
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intersting .. chart
Quote:
Originally posted by Scoobie Steve
I think you are confused, ]
cept that the air to water flows >50cfm more than the black air to air according to your chart ..the light purple line is pointless because you ARE using the feed pipe

grumblegrumblesoldmyairtowaterforanairtoairgrumble
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Old 05-17-2004, 11:14 PM   #16
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Quote:
cept that the air to water flows >50cfm more than the black air to air according to your chart ..the light purple line is pointless because you ARE using the feed pipe
That is true but the inlet pipe is easily upgraded to a smooth silicon which will improve the "w/feed pipe" flow greatly on all of those intercoolers except the air-water. The air-water can not be upgraded because the inlet pipe is a cast part of the cooler. I think the red line is totally bogus. It shows the tiny air-water cooler flowing nearly as much as a very large V7 bar and plate aftermarket intercooler, thats not possible!! The only numbers i trust are the "core flow numbers" And i know for a fact the air-water intercooler has the smallest core out of all the suby intercoolers.

That chart shows how restrictive the stock plastic inlet pipe is. Once the pipe is upgraded the core flow will be the major restriction.

Last edited by Scoobie Steve; 05-17-2004 at 11:25 PM.
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Old 05-18-2004, 01:54 AM   #17
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It has the smallest core because it using WATER cooling, it doesnt need a huge freakin core to cool it like in an air-air intercooler. It doesnt need the same circulation as a air-air. BUT, the flow rate from the turbo to the inlet as that chart shows, is VERY good. And about that "welded inlet" its still one of the largest stock intercooler inlets subaru has ever made. Its giant.
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Old 05-18-2004, 11:04 AM   #18
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you have never seen a black or air to water intercooler have you

#1 the "black" air to air charge pipe is not replaceable with silicon it is a cast plastic considerably differnt than the flex pipe on say a usdm intercooler

#2 size of the core has nothing to do with the density of the core air to water is a differnt animal than air to air

#3 the only numebrs that are worth a dam are the numbers w/ the feed pipe .. with out it you get have a N/A engine

#4 i am with kosta here i believe the air to water has such a good feed pipe numbes is that is cast into the housing design ..it is a very well done piece
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Old 05-18-2004, 02:45 PM   #19
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For the last time.... its the Aluminum one. It's even BETTER then the black one u n00b! LOL!
Plus all my hosing and stuff is totally custom anyway. The whole damn car is.
Plus...why the hell would STI's and WRX's upgrade to this intercooler if they didnt have the $ to drop 1500 bucks on a super intercooler?
Hmmm...maybe because its better

SOMEONE HOST PICS, and stop the arguement about AWIC's
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Old 05-18-2004, 02:45 PM   #20
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OH, I forgot to thank you as well JAXX, you helped out some too
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Old 05-18-2004, 05:46 PM   #21
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black one


air to water
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Old 05-18-2004, 05:53 PM   #22
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Then there is also the Silver Air to water
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Old 05-18-2004, 06:22 PM   #23
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There are both silver and black painted air-water intercoolers, the only difference is the car they came on!!! I dont know who told you the silver one is better. IIRC the black ones are JDM and silver ones are Aus and/or UK.

I have never seen a wrx or sti with this intercooler. These intercoolers go for about $40. If these really are as great as you claim everyone should be using one. Just so you know i had the silver air-water cooler on my car years ago so i hope you were not calling me a n00b! Oh and jaxx i have seen an air-water intercooler! And the core size is directly related to flow, thats what i am taking about FLOW, yes the core can be smaller because air-water is more efficient, but with a smaller core comes less flow! less passages for air to flow through the cooler. I will agree the cast inlet pipe is good but the core is the restriction! If this cooler is so great why didnt subaru use in on the STi or even the wrx's of the time.


Last edited by Scoobie Steve; 05-18-2004 at 06:52 PM.
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Old 05-18-2004, 06:41 PM   #24
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Quote:
Originally posted by Structure828
why the hell would STI's and WRX's upgrade to this intercooler if they didnt have the $ to drop 1500 bucks on a super intercooler?
Hmmm...maybe because its better



Thats funny... There are very few Air to water wrxs around, and most of them are using custom systmes. That flow both water and air better then subarus system. Now its a good system, espicaly if you live in a area where heat soak is a problem. Or your only other option is the old style ICs. But its got nothing on a ver. 7 or even wrx IC. Water just cant keep the heat out long enough, now if you could add fresh cold water every few laps...


Some reading on them if you want...
http://forums.nasioc.com/forums/show...hreadid=381610

http://forums.nasioc.com/forums/show...hreadid=215414

http://forums.nasioc.com/forums/show...hreadid=386782

http://forums.nasioc.com/forums/show...rcoolers+water
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Old 05-18-2004, 07:00 PM   #25
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Yea, most WRX's or even STI's do add those AWIC's if they can. Its hard to get them that cheap...by the way...the whole black and silver color thing u got it wrong. JDM is SILVER and AUS/NZ/UK is black. How do I know this? Because I own one
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