Welcome to the North American Subaru Impreza Owners Club Friday September 19, 2014
Home Forums WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Here you can view your subscribed threads, work with private messages and edit your profile and preferences Home Registration is free! Visit the NASIOC Store NASIOC Rules Search Find other members Frequently Asked Questions Calendar Archive NASIOC Upgrade Garage Logout
Go Back   NASIOC > NASIOC Technical > Subaru Conversions

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.
* Registered users of the site do not see these ads.
Reply
 
Thread Tools Display Modes
Old 07-09-2004, 08:31 AM   #51
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

I forgot to mention something - my poor stock clutch. It had been sitting on the car, still bolted in. We pulled it because the Exedy Twin-Plate does not come with a pilot bearing for the included flywheel. Anyway, I wish I had a picture. It was the saddest clutch I've seen that hadn't exploded. The material had been displaced around the disc, filling most of the grooves and many of the rivet holes. There were visable fibers on the surface, and fibers hanging out the edges. I'll try to remember to get a picture and post it tonight - it's must see TV.

-Sean
* Registered users of the site do not see these ads.
big_adventure is offline   Reply With Quote
Old 07-09-2004, 09:24 AM   #52
jamesfacts
NASIOC Supporter
 
Member#: 51282
Join Date: Dec 2003
Chapter/Region: Tri-State
Location: Brooklyn NYC / Danbury CT
Vehicle:
98 RS
black & blue from parking

Default



Thanks for the great pics - it'll be a big help when I start my swap... someday!
jamesfacts is offline   Reply With Quote
Old 07-09-2004, 10:28 PM   #53
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

A little bit more news -

The engine is ALMOST ready to rock. RC sent out a newly machined set of injectors yesterday. I called them and got the tracking number. When I punched it into Google to get to UPS, I got some bad, bad news. They were accidentally shipped 3-day, not next day. No!

A quick phone call to RC took care of things as well as possible, and they machined another set and have shipped them next-day, for Saturday delivery. That's all good, as long as they arrive.

I went back to the shop today for a little more tech-work. I put on the PS pump (we were missing a bolt), the alternator and the tensioner, and got the belts back on. Then I re-installed the radiator and the coolant hoses. I put on the downpipe and the catless midpipe from TXS, and wired up the rear O2 and my wideband. I, after 2 hours and fashinoning a tool with a die grinder, managed to move the ECU pins and then the driver's side harness pins to support AVCS. I still have to wire in the shielded wiring to support the AVCS cam sensors, and for that I need some Honda or Subaru harness pins. Once I have them, that's set. When the injectors arrive, I'll install them, reattach the coolant tank and fuel system, plug my FMIC pipes back in and dial in a base tune on the UTEC. A little coolant and oil, and that should be, as they say, that! Hopefully tomorrow evening I'll be writing a success story.

Ah, one other thing - the bolts that run through the spring connector at the donut gasket between the midpipe and the catback are pretty heat-fried. So much so that one broke while I was tightening it today. I hope I can find a decent bolt in the shop...

-Sean
big_adventure is offline   Reply With Quote
Old 07-12-2004, 11:29 AM   #54
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Well, all, I can't officially announce success yet, but I expect to tonight.

Saturday, I went back into the shop to "finish". There wasn't much to do, and I expected to knock it out in no time. Ben and I went to a salvage yard to clip a harness connector from a Civic to get some harness pins. I had already scored some ECU pins off of a Nissan throw-away harness. With these connectors, some solder, some heat-shrink and some work, I made my shielded AVCS cam sensor harnesses. Wiring them in was a snap, after figuring out the ECU and underhood pin workings the day before.

The RC injectors arrived at my place, so Ben and I took a non-boosted, rental Focus powered trip up to my place to pick them up.

These injectors were VERY different in machining than the last set. I have a picture that I will post later. I slid STi O-rings AND the RC O-rings onto the pintle, because I was a little worried that it wouldn't seal well. It didn't feel all that "positive" when I placed it in the port, because the injector body contacts the top of the port when the injector is all the way inserted. It contacts it very evenly, though. The RC injectors are much larger, so you a) need a lot more clearance on the rails and b) need to use spacers on the rail bolts. RC includes the spacers, so that's no problem. To get the clearance, you have to take off the two main fuel-rail bolts, and the pipe-support bolt on the side of the risers. On the passenger side, this is almost impossible. The oil-pipe for AVCS runs directly in front of the side bolt, while the fuel-rail runs directly over the banjo-bolt that secures the oil-pipe onto the engine. After some massive struggles, I got the banjo-bolt out and then the rail side bolt out. The rail side bolts are not reused with the RC injectors, as they no longer fit. I installed the injectors, cranked the rails down into place, connected the injector clips that I soldered on earlier, and we were good to go.

I connected all of the remaining tubes and hoses and connected all of the clips. Well, almost all, more on that in a minute.

We filled the car with oil (Mobil 1 and Marvel Mystery Oil), poured in some coolant, water and Water Wetter and discovered the first mis - there was a coolant leak thanks to a missed hose, but we got that sealed right up, and filled it as well as possible while cold.

Then, we gave it another too-quick once-over and I switched to the RA Spec-C ECU. I first turned it on without starting it up to tune the UTEC - I wanted a blank fuel map, wastegate boost only and to change the OLF settings to reflect the new injectors.

I then cranked the car to life. Well, it ran. It also had a CEL, ran like CRAP and clearly had some problems. It actually idled. Rougly, but it did. You'll see why that impresses soon...

First, the vacuum leak. The fitting for the brake-booster is replaced with the APS DR500 I/C, and this fitting was under the post-turbo charge pipe. When we pulled the motor, somebody in there must have tucked the hose out of the way, and I couldn't easily see either the host or the fitting, and I missed it. We could hear it clearly, we found it, connected it and restarted the car.

It again cranked right up, but it again ran like garbage. It managed to correct itself at idle, but it was horribly rough. We ran it for a while like this and warmed it up, just waiting to see what was up and also wanting to bleed in some coolant. We then started looking for a problem. We couldn't hear a vac leak, and couldn't find one. this makes sense, because the problem was much, much simpler. When I was installing the injectors, I had disconnected the coil-pack wires to #2 and #4 to get some harness clearance to work. So the car was sitting there, managing a rough idle with TWO DEAD CYLINDERS AND a MASSIVE VAC LEAK. Ben was a bit freaked out by this - it shouldn't have been possible, so we plugged in the harness and left the building.

On Sunday, I went back in and we again cranked the little blue car. Again, it ran like crap, clearly in limp-mode. We finally pulled the CEL, and got a P0031, Heater Circuit CEL. Damn, that meant front O2 sensor. I had been playing with pins and wiring, and it's POSSIBLE that the 04 harness is different enough to make it impossible to work with the 02 RA Spec C ECU. I had the FSM handy and printed out, and reviewed the wiring diagram. Nope, I didn't mess with that ECU connector at all. Just to be sure, I did a continuity test on all of the appripriate wires, from ECU pin to harness end in then compartment. Everything was good. We then lifted the car and noticed that two of the wires on my front AF sensor were cut! An easy solution, but a disheartening one - it was Sunday, and Subie parts departments aren't open on Sunday. There is no aftermarket A/F sensor for these cars, so we were stuck. I tried to find a local with an extra A/F, but had no luck at all.

Today is Monday. Ben is picking up the new front A/F today, and tonight I'll install it. Then, she rides...

-Sean
big_adventure is offline   Reply With Quote
Old 07-12-2004, 11:48 AM   #55
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

WRX8XB is offline   Reply With Quote
Old 07-13-2004, 12:28 AM   #56
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Talking Done!!!!!

She is a MONSTER.

I put in the new O2 sensor and everything is perfect. I see -480mmHg of vacuum at idle. The motor is smoother and quieter than my stock motor, despite the more agressive heads and cams. I'm a bit rich right now, around 10.5:1 at WOT, and my timing is still the timing I used on my stock motor, so there's a lot more in her, but I had it out for a while tonight, and hit 22-23psi on 93 octane gas with NO DET AT ALL! This engine is awsome.

About that boost - I have a Garett GT30R-11 turbo, and it's a custom job. The wastegate is only an 8psi gate, so I put a big, fat helper spring on it to build and hold boost better. On my stock motor, with the high-flow cat from TXS in place, that gave me 17.5-18psi as my wastegate pressure. With the new motor, and no cat, it's a massive difference - 22-23psi wastegate (my CLB settings are 1. Everywhere). Getting rid of that backpressure made my turbo even more alive than before!

I'm also breaking in (and getting used to) my new Exedy twin-plate clutch.

The good things:

- It'll hold 600+ lb/ft of torque. My last clutch looked like salt-water taffee.

- The pedal effort is not much harder than stock, very positive.

- The entire clutch, flywheel, mid-plate and pressure plate combination weighs only ~30lbs - can you say "fast revving"?

The bad things:

- Sure, it only has 35 miles on it, but there is definite, pronounced, loud chatter when the clutch is disengaged.

- If you want a smooth, slipping launch, you have to pull into it at over 2K revs and balance the throttle perfectly.

Ah, well, it's a race part, so there are sacrifices. It's totally drivable, it just took me 10 minutes to get used to it. It's kind of like driving a sport-bike for the first time - you don't want to smoke the tires every time out, so you take it easy. Then you stall it at a light. Woops. No stalls so far here, but there have been a couple of stiff launches.

But it'll hold the power. If I never have to change the clutch on the car, it'll be a little too soon for me. I've seen her in pieces too much lately.

Anyway, I'm really looking forward to tuning her and hitting it hard soon, but I need to wait a couple of weeks to break in that clutch. More when it happens!

There is one, expected caveat - I'm using the Rev6 US UTEC with the JDM ECU, so I do get the 4 "harmless" injector OBDII codes, P0261, P0264, P0267 and P0270. These are expected, and cause no issues at all that anyone can see.

There is one, unexpected caveat that I still haven't completely resolved - I get a clunk somewhere from the exhaust hitting the tranny or the frame. It only happens when I do something harsh with the transmission or hit an awkward bump when I'm in gear but off the throttle. The exhaust hangers helped some, but I'm going to need to find a solution. I think it is caused by the transmission's exhaust bracket on the STi 6MT being MUCH longer and thus MUCH more flexible than on the 5MT - where I never got this. I think I'll reinforce that bracket with some metal plate. We'll see.

Current mod list:

2004 WRX wagon
V7 STi RA Spec C engine and ECU
V7 STi 6MT transmission
STi gold Brembos
STi axles
R180 rear diff
STi trailing arms
Tein coilovers
Rota Torque 17x8 wheels, steel grey
UTEC
TXS TBE (non-RFL) with race pipe
Garett GT30R-11 turbo (Ported AVO 320 turbine housing .63 A/R, Turbonetics T04 comp cover)
APS DR500 FMIC
APS BOV
RC Engineering 750cc Injectors
Perrin catch can
Kartboy exhaust hangers
Exedy twin-plate clutch
GReddy electronic boost and EGT gauges
TXS Tuner (Da Tuna!) WbO2

You will see more from this soon!

-Sean

Last edited by big_adventure; 07-13-2004 at 09:18 AM.
big_adventure is offline   Reply With Quote
Old 07-13-2004, 06:31 AM   #57
Pacobeagle
Scooby Specialist
 
Member#: 8775
Join Date: Jul 2001
Chapter/Region: South East
Location: Mobile,AL
Vehicle:
2010 "Zed" 1000
Orange/White

Default

Glad to hear that everything is in order. NOW TAKE ME FOR A RIDE!!!!!! I put in enough time for a 4WD burnout. No seriously, break her in, tune the car and then come see me.

Cheers to a sick wagon in Fl. that one day I'll own.

jose
Pacobeagle is offline   Reply With Quote
Old 07-13-2004, 09:20 AM   #58
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Thanks Jose, you still have dibs if/when I sell her. BTW, AVCS worked first try. I logged it with DD this morning and saw it laying in up to 16 degrees of advance on the intake cams.

-Sean
big_adventure is offline   Reply With Quote
Old 07-13-2004, 09:55 AM   #59
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

so...how much are you charging for rides? are kids under 4 half off if they bring their own recaro baby seat?

Drew

(congrats on the install (do we get a full write up?))
WRX8XB is offline   Reply With Quote
Old 07-13-2004, 11:35 AM   #60
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Really cheap until the clutch finishes breaking in...

As far as full write up, I'll post some pics to complement this stuff, but I'm not sure how much more I really need to type!

Quote:
Originally posted by WRX8XB
so...how much are you charging for rides? are kids under 4 half off if they bring their own recaro baby seat?

Drew

(congrats on the install (do we get a full write up?))
big_adventure is offline   Reply With Quote
Old 07-14-2004, 01:11 PM   #61
roffle
Scooby Newbie
 
Member#: 42251
Join Date: Aug 2003
Chapter/Region: E. Canada
Location: Ottawa, Ontario
Vehicle:
uh oh
trumpet butt

Default

wanna trade?
roffle is offline   Reply With Quote
Old 07-14-2004, 05:03 PM   #62
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Quote:
Originally posted by roffle
wanna trade?
Let me think about it




















Nope, don't think so!

-Sean
big_adventure is offline   Reply With Quote
Old 07-14-2004, 07:30 PM   #63
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

is the exedy twin plate unit broken in yet?

Drew
WRX8XB is offline   Reply With Quote
Old 07-15-2004, 08:32 AM   #64
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Up to 290 miles so far. Over 5-600, she'll be ready to go.

I'm thinking of putting her on the dyno next weekend - though I haven't called Twilight just yet.

-Sean
big_adventure is offline   Reply With Quote
Old 07-15-2004, 09:28 AM   #65
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

well keep us posted on that!! I assume you're gonna use "Da Tuna"

Drew
WRX8XB is offline   Reply With Quote
Old 07-15-2004, 10:24 AM   #66
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Of course, I use it every day...

I have to finish breaking in the clutch before I tune the beast on the street. Once I've done that, we're dyno-bound.

-Sean
big_adventure is offline   Reply With Quote
Old 07-19-2004, 12:12 PM   #67
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Well, I'm up to 600 miles on the clutch, and it took a hard pull to 8200 this morning at 1.6bar on pump gas. This engine is amazing - we already knew that about my turbo. It's a very, very good match. I'll do some road tuning this week - there are some fairly mild hesitation issues where the crossovers happen - it's a big jump from the agressive RA timing.

-Sean
big_adventure is offline   Reply With Quote
Old 07-19-2004, 12:16 PM   #68
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

morosso test and tune?

Drew

Last edited by WRX8XB; 07-19-2004 at 12:25 PM.
WRX8XB is offline   Reply With Quote
Old 07-19-2004, 02:21 PM   #69
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Not quite yet, plus, I have to work late on Wednesday.

-Sean
big_adventure is offline   Reply With Quote
Old 07-19-2004, 02:24 PM   #70
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

ok, ok. I had to ask. I guess it makes sense to tame the beast before you let her out of her cage.

Drew
WRX8XB is offline   Reply With Quote
Old 07-19-2004, 02:29 PM   #71
big_adventure
Scooby Specialist
 
Member#: 40501
Join Date: Jul 2003
Location: Paris, FR
Vehicle:
2005 Decathalon 21sp
One WheelSeanPower

Default

Yeah, and like I said, I have to do something about overboosting. Which simply means switching out to a softer spring on my gate, I guess, and then maybe going for an MBC or something.

-Sean
big_adventure is offline   Reply With Quote
Old 07-19-2004, 03:51 PM   #72
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

so 1.6 bar is more then you want to run? What is your target boost?

Drew
WRX8XB is offline   Reply With Quote
Old 07-21-2004, 01:04 PM   #73
roffle
Scooby Newbie
 
Member#: 42251
Join Date: Aug 2003
Chapter/Region: E. Canada
Location: Ottawa, Ontario
Vehicle:
uh oh
trumpet butt

Default

bump!!!

Love this thread!!
roffle is offline   Reply With Quote
Old 07-21-2004, 04:16 PM   #74
WRX8XB
Scooby Guru
 
Member#: 45323
Join Date: Oct 2003
Chapter/Region: MWSOC
Location: Iowa
Vehicle:
MY05 Impreza WRX STi
Pastelito Racing & SFSOC

Default

Yea sean we love this thread and we want updates!!

do you have any pics of it all installed? hood open of course

Drew
WRX8XB is offline   Reply With Quote
Old 07-21-2004, 04:22 PM   #75
HOK
Scooby Specialist
 
Member#: 447
Join Date: Oct 1999
Location: Oh Canada
Vehicle:
1999 EJ22T222B&EVO
Are we racing yet?

Default

sigh... who knew one could be so jealous of metal...

not just about hot girlfriends anymore....
HOK is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
05 STI swap into 04 WRX Wagon. HELP! pismobeachrider25 Built Motor Discussion 6 04-12-2010 09:58 AM
Full USDM STi Drivetrain into MY06 2.5i Boosted WRX STi Subaru Conversions 12 05-02-2008 09:15 PM
OEM 04 STI suspension into 05 WRX wagon javi-sti Newbies & FAQs 3 11-05-2007 01:17 PM
STi drivetrain into 07 WRX St3fan Newbies & FAQs 10 02-12-2007 11:58 PM
sti tranny into 04 wrx wagon? sakebomb Subaru Conversions 1 07-08-2004 02:34 PM


All times are GMT -4. The time now is 06:34 AM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2014 Axivo Inc.
Copyright ©1999 - 2014, North American Subaru Impreza Owners Club, Inc.