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Old 12-08-2017, 03:26 PM   #1
envader
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Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default envader's 2005 Saab 9-2X Aero - full STi swap!

What's up everyone! I've been a member of the Subaru community since February of 2015, when I picked up a 2015 WRX from Stivers in Decatur, GA. A few months ago, I swapped it out for my current vehicle: a 2005 Saab 9-2X Aero, with a full STi swap!



I picked up the car from another member back in early August. He threw a bearing in the original motor, and decided to swap in a longblock from a 2006 EJ257. For those of you that don't know (like me before I bought the car), this is a complicated, confusing, and time-consuming swap. The 2005 Aero is essentially a WRX wagon from a powertrain perspective, which means that it is powered by an EJ205 w/ 16-bit drive-by-cable ECU and throttle-body. The 2006 STi is obviously powered by the EJ257, and has the 32-bit drive-by-wire ECU and throttle-body. That means in order to retain the factory ECU (in order to keep the gauge cluster, reverse lights, etc. working), there are a number of things that set this apart from a regular "STi swap", such as retaining the WRX intake manifold and throttle body, customizing the WRX engine wiring harness, deleting the AVCS system, etc. It would have been MUCH, MUCH easier to do a hybrid build (EJ257 block w/ EJ205 heads) in my opinion, but that's what the previous owner decided to do, so oh well! The longblock had about 85k miles when installed.

In addition to the 2006 EJ257 longblock, the previous owner also swapped in a full 6-speed drivetrain that was originally on a 2007 STi: transmission, differentials, axles, hubs, etc. The STi drivetrain also had about 85k miles when swapped in. Also he added the legendary MAP DCCD controller - whoo!

Here are the build specs as it was when I picked up the vehicle:

-EJ257 longblock from 2006 STi
-Full 6-speed swap from 2007 STi
-SPT intake
-Perrin 2.4" silicone turbo inlet hose
-VF48 from a 2015 STi
-Cobb turbo heat shield
-2008 STi TMIC
-TGV deletes
-Stock fuel rails, lines, and FPR
-Stock fuel pump
-ID1000 injectors
-Cobb 3-port BCS
-Grimmspeed EWG uppipe w/ dump tube
-Tial MV-S
-Invidia catless DP
-Prodrive Axleback exhaust w/ stock mid-pipe
-KillerB Pick-up tube and windage tray
-Group N Motor, transmission, and pitch-stop mounts
-IAG Competition-series AOS
-MAP DCCD controller

After driving it back to Colorado, the first order of business was to get it to pass emissions. As it was, I failed with flying colors, so I needed a catted downpipe ASAP. Instead of just swapping out my catless for a catted aftermarket DP, or going back to stock DP, I opted to have one of the brand-new GESi 49-state legal catalytic converters welded in to my existing catless DP. I wasn't a huge fan of the EWG venting to atmosphere either, so I had the dump tube routed into the DP at the same time.



After owning the car for about a month, I took it up to see Harvey (aka TheBoostCreep) up in Longmont for a set of proper high-altitude tunes. I got it tuned on both 91 and E85, but my results were pretty disappointing w/ the mods that I had: 248whp on 91 @ 16psi, and 289whp on E85 @ 20psi. While tuning, Harvey mentioned that he was getting a lot of what he thought was false knock. At the time I just attributed it to ****ty quality gas and/or the turbo just not liking how the dump tube got routed..



About a month after I got the new tune, my dash lit up like a Christmas tree when I was driving home. Misfire codes, EVAP purge valve low voltage codes, etc. Fearing the worst, I asked a local shop to do a compression test for me... and ended up getting the bad news I was expecting. Low compression (~70psi) on cyl 2. Scheisse. Time for a new short block!
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Old 12-08-2017, 03:37 PM   #2
envader
Scooby Newbie
 
Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default

I decided to go with a "stage 1" block from a local builder: Stock STi case halves w/ new nitrated crank shaft, stock STi rods w/ ARP Fasteners, King race rod and main bearnings, and Manley Platinum-series 8.2:1 forged pistons. With the ARP fasteners, the STi rods should be good to about 550whp.

While the car is down getting the new block, I decided to do some power upgrades because race car. Here is the final set-up I am going with:

-Built EJ257
-TurboXS short-ram intake
-FP 84mm hard turbo inlet
-FP Red w/ 8cm turbine housing (GT35R compressor wheel, rated at 65 lb/min)
-TurboXS FMIC
-TGV deletes
-IAG v2 top feed fuel rails w/ dampeners
-Aeromotive FPR
-IAG braided fuel lines
-DW300c fuel pump
-ID1000s
-EWG up-pipe routed to catted DP
-3" catback
-Stg2 Clutch

I'm hoping to make around 425whp on E85. I know my limiting factor is going to be the injectors, as well as the stock exhaust manifold, so those will be my next upgrades in a few months.

I should be picking it up in the next couple of weeks - review and thoughts coming shortly! Thanks for reading everyone.

Last edited by envader; 03-05-2018 at 03:23 PM.
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Old 03-05-2018, 03:07 PM   #3
envader
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Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default

Little update.. finally got this thing back from the builder. Currently still breaking in the engine, but should be ready to turn the boost up by this weekend.

Wanted to go ahead and put the full mod list here.

BLOCK:
EJ25 case halves bored to 100mm
Manley Platinum-series forged pistons (8.2:1)
OEM rods w/ ARP rod bolts
King Race rod/main bearings
New STi nitrated crankshaft
B25 heads w/ new valves, springs
OEM non-AVCS camshafts

AIR:
SPT Intake
Forced Performance 84mm Turbo Inlet
Forced Performance RED turbo (w/ 8cm turbine housing)
TurboXS Front-Mount Intercooler
GoFastBits Respons Hybrid BOV
Cobb 3-port BCS
OEM drive-by-wire throttle body
OEM intake manifold (top feed)
TGV Deletes
AEM wideband sensor
IAG MAP sensor adapter
AEM 3.5bar MAP sensor

FUEL:
Injector Dynamics ID1000 injectors
IAG v2 Top-Feed Fuel Rails w/ dampers
IAG braided fuel lines
Aeromotive A1000 fuel pressure regulator
Deatschworks DW300c fuel pump

OTHER ENGINE:
IAG Competition series air-oil separator
Mishimoto Performance aluminum radiator
KillerB oil pickup tube
KillerB windage tray
Cobb relocated coolant reservoir
Cobb turbo heat shield

EXHAUST:
Stock exhaust manifold
Grimmspeed EWG uppipe
Tial MV-S 38mm EWG w/ dump tube routed to downpipe
Invidia bellmouth downpipe
Vibrant GESi UHO-series catalytic converter
3" midpipe (unknown brand)
ProDrive axle-back

DRIVETRAIN:
6-puck clutch (unknown brand)
2007 long-ratio STi 6-speed transmission
2007 STi DCCD
MAP DCCD controller
2007 STi front and rear axles
2007 STi driveshaft
2006 STi R180 rear differential (clutch-type)
2007 STi 5x114.3 hubs, knuckles, and bearings

SUSPENSION/BRAKES:
2007 STi front and rear gold Brembos
StopTech Powerslot front and rear rotors
StopTech Sport brake pads
STi front and rear strut assemblies
OEM sway bars

WHEELS/TIRES:
OEM STi BBS 5x114.3 17x8 +53
Continental ExtremeContact DWS 235/45ZR17

Last edited by envader; 03-05-2018 at 08:55 PM.
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Old 03-11-2018, 12:45 PM   #4
D-Rodman
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Member#: 110078
Join Date: Mar 2006
Chapter/Region: Tri-State
Location: Long Island N.Y.
Vehicle:
05 Saabaru JDM STi
Black Ver 7 VF48 6sp RA

Default envader's 2005 Saab 9-2X Aero - full STi swap!

A ej207 motor wouldíve been a simple swap and could have kept avcs, good luck with the ej257. Letís see the dyno graph, curious to see the power curve without avcs on a 2.5l.
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Old 03-23-2018, 03:22 PM   #5
envader
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Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default

Quote:
Originally Posted by D-Rodman View Post
A ej207 motor wouldíve been a simple swap and could have kept avcs, good luck with the ej257. Letís see the dyno graph, curious to see the power curve without avcs on a 2.5l.
Yeah.. if I could go back and do it all again, I would have done an EJ207 swap instead. Oh well.

Unfortunately I don't have a dyno graph, but here's the datalog from my latest revision of my tune from Eric @ Torqued Performance:



https://datazap.me/u/envader/rev15?l...ta=4-5-7-10-16
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Old 03-23-2018, 03:29 PM   #6
envader
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Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default

So - done with e-tuning for now, unfortunately I'm pretty disappointed with how the power curve turned out. As it is, I really only have "usable" power between 5-7k rpm.

I'm very heavily considering getting a different turbo that will spool up a little quicker.. maybe I'll just go twin-scroll while I'm at it, since I need to upgrade my headers anyway. I miss my 2015 WRX!
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Old 03-24-2018, 09:50 PM   #7
D-Rodman
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Member#: 110078
Join Date: Mar 2006
Chapter/Region: Tri-State
Location: Long Island N.Y.
Vehicle:
05 Saabaru JDM STi
Black Ver 7 VF48 6sp RA

Default

Iím sorry to hear you are disappointed, I know how that feels. I also have a swapped 2005 Saabaru, I did a full ver 7 jdm STi drive train, I have an ej207. When I did my swap I purchased a brand new Blouch 18G XTR and all supporting mods. After 4200 miles I removed the Blouch because I didnít like the drivability. It was awesome if I took off the line, put the pedal to the floor and kept it on boost. Normal driving around town it was also good but on the highway it forced me to go from 6th to 4th gear in order to get proper acceleration to move quickly thru traffic. If I shifted into 5th I still had to work the gas pedal before i could really step on the gas pedal. I just swapped a VF48 into it, had SoCal Porting port it and polish it as they promise about 200 rpm quicker spooling. I do have functioning avcs, Iím hoping drivability will be improved. Iím also going back to a stock air box, waiting on a replacement bottom half of the box to arrive. Found a crack on the original air box. Started the car for the first time since December, notice a small antifreeze leak from the lower antifreeze pipe/hose area and fuel leak on the fuel damper area. Have to iron out those kinks and wait for the roads to clean up. I donít use the car when the roads are salted. I have another 05 Saabaru for daily driving. The daily driver just got a jdm wrx ej205 motor swap about 5,000 miles ago, it is also avcs wired but just a basic stage 2 with the original jdm td04. Its awesome, the fast spooling td04 and functional avcs gets it going quick, I can stay in 5th gear and get thru traffic without drama or hassle, love it.
I suspected your setup without functional avcs would make for late power delivery. I can see why youíd miss your 15wrx. I had a 02 bugeye wagon I swapped a ver 8 jdm STi ej207 into, that was just a basic stage 2 setup with the stock twin scroll vf37 and that thing spooled like a mother. It was amazing and it was mated to the stock 5 speed, I miss that car too. Sold it to a good friend, he still has it, still on the original 5 speed putting down 308 ft pounds of torque to the wheels at 3550rpm. I hope you figure out a setup you can live with man.
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Old 04-01-2018, 10:42 PM   #8
envader
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Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default

Spring is here in Colorado, decided to clean her up a bit. Enjoy the pics.





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Old 04-01-2018, 11:49 PM   #9
dev6565
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Member#: 424131
Join Date: Jun 2015
Chapter/Region: South East
Location: Clarksville, TN
Vehicle:
2006 WRX Limited
Aspen White

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Great looking Saab! I love these things and am looking forward to getting one as a daily. At the moment though there are very few decent shape looking examples posted for sale and are also decently priced.
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Old 04-04-2018, 06:15 PM   #10
envader
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Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default

Quote:
Originally Posted by dev6565 View Post
Great looking Saab! I love these things and am looking forward to getting one as a daily. At the moment though there are very few decent shape looking examples posted for sale and are also decently priced.
True that, brother. There is a facebook group (Saab 9-2X Club) that sees a few more posts than your typical cars.com or craigslist searches, but they are still pretty hard to come by. I will keep my ear to the ground for you!
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Old 04-04-2018, 07:24 PM   #11
dev6565
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Member#: 424131
Join Date: Jun 2015
Chapter/Region: South East
Location: Clarksville, TN
Vehicle:
2006 WRX Limited
Aspen White

Default

Quote:
Originally Posted by envader View Post
True that, brother. There is a facebook group (Saab 9-2X Club) that sees a few more posts than your typical cars.com or craigslist searches, but they are still pretty hard to come by. I will keep my ear to the ground for you!
Hey thanks man I appreciate it!
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Old 04-10-2018, 02:19 PM   #12
envader
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Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default

Quote:
Originally Posted by dev6565 View Post
Hey thanks man I appreciate it!
Just saw this:
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Old 04-10-2018, 02:35 PM   #13
D-Rodman
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Member#: 110078
Join Date: Mar 2006
Chapter/Region: Tri-State
Location: Long Island N.Y.
Vehicle:
05 Saabaru JDM STi
Black Ver 7 VF48 6sp RA

Default

That is potentially a good buy.
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Old 04-11-2018, 01:12 PM   #14
envader
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Member#: 414827
Join Date: Mar 2015
Chapter/Region: RMIC
Location: Denver
Vehicle:
2005 9-2X STi
Arctic Silver

Default

Quote:
Originally Posted by D-Rodman View Post
That is potentially a good buy.
Yeah I agree.. $4500 for a running WRX wagon is a good deal no matter what way you slice it.
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Old 04-12-2018, 01:29 PM   #15
Zee Biker
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Member#: 166005
Join Date: Dec 2007
Chapter/Region: MWSOC
Location: Northern 'Burbs
Vehicle:
2005 Saab 92x
Beaten Silver

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Old 04-12-2018, 05:29 PM   #16
D-Rodman
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Member#: 110078
Join Date: Mar 2006
Chapter/Region: Tri-State
Location: Long Island N.Y.
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05 Saabaru JDM STi
Black Ver 7 VF48 6sp RA

Default

Those graphs are for engines with functional avcs, op has no avcs, if he did have working avcs heíd be spoiling 1,000 rpm earlier.
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Old 04-13-2018, 08:19 AM   #17
Zee Biker
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Beaten Silver

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Quote:
Originally Posted by D-Rodman View Post
Those graphs are for engines with functional avcs, op has no avcs, if he did have working avcs he’d be spoiling 1,000 rpm earlier.
Since we are at it, he is running a lower quality front mount and is at elevation.

Your 18g would have been pretty cool for him as well!
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Old 04-13-2018, 11:05 PM   #18
D-Rodman
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Join Date: Mar 2006
Chapter/Region: Tri-State
Location: Long Island N.Y.
Vehicle:
05 Saabaru JDM STi
Black Ver 7 VF48 6sp RA

Default

VF48 should spool a bit quicker than the 18G Zee, thatís why Iím moving from the 18g to the VF48. Avcs helps a significant amount.
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Old 03-29-2019, 09:18 PM   #19
AlwaysBrokenBug
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That's a beautiful build I'd like to get there some day with mine.
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Old 06-19-2019, 11:00 PM   #20
Saab_Story
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Member#: 488724
Join Date: Jul 2018
Chapter/Region: NWIC
Location: PDX
Vehicle:
2005 Saab 9-2x Aero
Black

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I love this build! Always nice to see another Saabaru. Quick question, what sort off splitter did you use when running the TMIC?
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