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Old 05-05-2006, 10:42 PM   #1
dailo13
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Default JDM FXT Motor Swap into 02' WRX Cam Position Sensor Issue

Hello All,

My FXT motor just arrived from gruppe-s and unfortunately, already running into a snag. Based on element tuning's instructions (http://elementtuning.com/technical/ej25_install.htm, there should be a place right above the driver's side cam gear to mount the stock WRX cam position sensor. I only had to drill a hole and the sensor would mount correctly. Only problem is that my particular motor does not have this mount. If you can see on element's site, the mount is right above and to the right of the driver's side cam. I have removed the cam gear cover and the cam gear itself and still have not found it. It is not possible that my particular engine has the mount because the cam gear cover is too small. I don't know what to do at this point. Gruppe-s has said that there should be a hook and mounting boss on that side, but it just isn't there. The only possible place to mount a sensor is below the cam, but the pickup point would be behind the cam, thus picking up readings from the cam itself and not the cam gear. I don't think this is possible because the sensor is made the read the cam gear and not the cam itself. My mechanic is closed for the weekend, but on monday morning, I will go over to take pictures to show everyone. In the meantime, I was just wondering if anybody else's FXT motor was lacking the cam position sensor mount and if so, how in the world am I going to get around it? Also, the FXT sensors have 3 wires and the WRX has only 2, which wire do I clip? I appreciate any help anybody can give. My mechanic was already unhappy with my decision to try a swap instead of using the EJ205. He already has the "I told you so" face on

-Danny
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Last edited by dailo13; 05-09-2006 at 03:00 AM.
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Old 05-06-2006, 06:27 PM   #2
wrxfactor
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Danny, one of those wires is for AVCS. I am not sure how to identify it, possibly with a voltmeter and measure the power? I am curious as to the answer, as Gruppe-S just sent me the same motor and it is going in my 2002 WRX also. I only plan to run it like you are doing for my trip home in a week, then I am rebuilding my WRX heads and putting them on the motor as to eliminate the AVCS issue. The tuner doing my car in Austin, TX won't be there till Monday also, so I'll let you know anything I find out then.
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Old 05-08-2006, 02:29 AM   #3
02Toyowrx
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I just got some 2.5L AVCS heads and was contemplating the same problem. Here are the options for a solution.

1- Use wrx heads as you mentioned
2- use the 2.5L AVCS heads and rewire the car all the way to the ECU (using the 2.5L ECU) This would also require the use of a drive by wire intake manifold and throttle body and intercooler as well as the drive by wire pedal and wiring.

If anyone else has a better idea please let me know! As the 2.5L AVCS heads would require alot more parts and $$$
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Old 05-09-2006, 02:55 AM   #4
dailo13
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If you can check out element's site, there should be a mount above and to the right of the intake cam. I only see one under on the exhaust cam and on the cam itself, not the cam gear in the third picture. I dunno, sorta lost. Almost considering JDM ECU and new wiring harness and gas pedal. Anybody know how much wiring harnesses are to convert an 02' wrx to 05' STi (JDM FXT motor)? How much work involved, i.e, just swap harness in engine bay, and connect to new ecu? Boost sucks...until my car is done of course
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Old 05-09-2006, 09:20 AM   #5
snowjob
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I'd check to see if you can't find a ej20g (that is the one i'm positive of, but others may apply) Intake Cam bearing Cap, it has the sensor braket attached to it and would be what your looking for.
See on this EJ20 Twin Turbo how the Intake cam bearing cap holds the braket for the sensor. Might be worth a look at a wrecker to see if a n/a ej22 or ej25 has the same setup.
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Old 05-12-2006, 10:23 PM   #6
dailo13
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thanks snowjob for your advice. Quick question...will that bearing cap be enough to hold the sensor steady? I can't really see from the picture, but what I was supposed to do was tap a hole into a mount on the head itself which is solid metal. I would think a sensor meant to read a cam gear spinning at ?rpm would require a more solid mount than a bracket clipped onto plastic(cam gear cover). Right?

Quick update...cam gears were removed per instructions and still nothing there. So I now have no way of mounting my ej205 cam position sensor on this ej257. I think my only alternative now is to buy a wiring harness and splice it in. Anybody out there have a JDM V8 sti wiring harness and ecu? Or, does anyone know if I can machine through the pre-fab port on the bottom of the head like in my third picture. Thanks.
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Old 05-14-2006, 05:41 PM   #7
uberspeed
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I just mounted an ej20 cam sensor on my '04 USDM Baja Turbo EJ255 motor that is going in my 02 WRX. Looks like Subaru removed the cam sensor boss from the castings all together. I wonder when they did this. I guess I lucked out. From your pictures, you definately don't have the proper boss.

It would be interesting to know how similiar the original Ej257 CAM sensor signal is to the Ej205 CAMGEAR sensor signal. My guess is they are both hall effect sensors. Someone should figure out this so drilling and tapping isn't required.

Last edited by uberspeed; 05-14-2006 at 05:46 PM.
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Old 05-15-2006, 12:56 AM   #8
NicFunkadelic
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In the last close-up side shot, the cam position sensor fits into the larger hole, and then is secured by a bolt into the smaller hole... I think, unless I'm missing something... It does look slighly different than I recall.
Nick
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Old 05-15-2006, 09:41 PM   #9
dailo13
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uberspeed - did you mount the sensor on the boss meaning your engine cam with the mounting boss behind the drivers side intake cam? I can't use the sensor on the engine because they are for AVCS so the signal is off completely. That is why I need to find a way to mount my ej205 sensor somehow.

nick - The last pic I have posted shows the hole for the sensor on the head cover itself. I am pretty sure the cam itself does not have pickup points for the sensor, only the cam gear. Also, tapping a head cover sounds a lot worse than tapping a mounting boss.

Thanks for everybody's help so far. It is still a learning process for me and I do have a good mechanic doing the work for me, but he has a lot less patience than me. Especially since he didn't get to earn some money if I got an engine from his source instead of finding one on my own
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Old 05-15-2006, 10:41 PM   #10
uberspeed
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Quote:
Originally Posted by dailo13
uberspeed - did you mount the sensor on the boss meaning your engine cam with the mounting boss behind the drivers side intake cam? I can't use the sensor on the engine because they are for AVCS so the signal is off completely. That is why I need to find a way to mount my ej205 sensor somehow.
I mounted my EJ205 sensor because I am not using AVCS. I mounted it on the boss behind the driver's side intake cam. Just like the EJ205. I was wondering though, how different is the 3 wire EJ257 CAM sensor signal when compared to the EJ205 2 wire sensor signal? Maybe it is a simple transfer function written into your EM. But I have no idea.
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Old 05-17-2006, 05:16 AM   #11
gimmewar
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Is that sensor under any sort of stress? The tab for it broke off during shipping and I was worried about tolerances being affected if I were to just weld it back together (I've got a friend that works with aluminum and titanium that can weld it). Let me know what you guys think.

Mike
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Old 05-17-2006, 01:30 PM   #12
uberspeed
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Yeaks! It broke off during shipping? That sucks! If that was broke, other things surely got broken too eh?

It doesn't see any stress. Maybe some fatique from vibration but I wouldn't worry about it. If you get it lined up correctly you should be fine.

FYI, not only is the cam sensor boss not drilled and tapped, it is also missing a few machining steps so you sensor might not plop in. It will require a little filing but no big deal. Tolerance don't appear to be too critical with the sensor location judging by the size of the sensor mounting hole relative to the bolt that goes in it.
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Old 05-17-2006, 02:16 PM   #13
gimmewar
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Everything else checked out ok.

Mike
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Old 10-16-2007, 02:31 AM   #14
lo0nY
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has anyone found a solution for this? i'm running into the same problem
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Old 08-18-2009, 04:40 PM   #15
lo0nY
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one last try....serious this time...has anyone ran into this problem?
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