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Old 11-16-2019, 05:26 PM   #1
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default carnz' EG33 swapped 05 Forester

Picked up an Aspen White 05 Forester XS in the beginning of September after my 95 coupe got hit.



I was originally just going to swap in my full coupe setup (650whp on E85, built engine, etc...) but i figured another turbo EJ forester was too common and I wanted to challenge myself a bit.



I've had all the parts to build a big HP closed deck EG33 on hand for a year now with no vehicle to put them in, and so here we are!

I'm going to add more posts with some more info rather than squeezing everything i've done so far into one post.

TOC:
Post #1 (here), Intro.
Post #2 Acquiring the EG33
Post #3 Dropping in the test/mockup engine
Post #4 Engine Management
Post #9 Radiator install/fitment
Post #12 A/C Condenser and Intercooler install
Post #14 First start of the EG33!
Post #15 Deleting ABS, and installing throttle cable and pedal
Post #19 Steering Rack Swap, ARP Studs, etc...
Post #24 Front Control Arm Work/Overhaul
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Last edited by carnz-pj-410; 01-18-2020 at 04:47 PM.
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Old 11-16-2019, 05:34 PM   #2
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Last year, I decided to buy an EG33 from a buddy that had lost interest in his project.

He had a full EG33 in bins and the case halves were at OutFront motorsports for closed-decking. No internals were ordered, or even considered, but like i said, he had checked out of the project and was selling off his parts.



Now i had a pallet of parts, and a closed block(that was still at OutFront), and a half-assed plan to build a monster engine.

Next up, I called Jeremy at OutFront and got custom CP pistons ordered up, and had the block machined for ARP 1/2inch head studs while he still had it there. A few weeks went by waiting for the pistons, and then finally it arrived!







Excitement is building!
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Old 11-16-2019, 05:41 PM   #3
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

I haven't assembled the built engine yet (currently in the process of porting the heads before i send them out to be decked).

Wanting to get started on the project (goal is to be tuned by April/May), i picked up a spare complete EG33 to drop in which allows me to get the exhaust fab work finished and get the wiring and ECU sorted. I feel safer testing the ECU setup on a stock engine vs my built engine.

The "spare" EG got delivered a week or two ago, in OK but running condition ( good enough to get everything setup)


Last saturday we pulled the EJ253 out and dropped in EG in to get an idea of how everything fits.




And it's in!

As expected, it's a super tight fit and will require some custom work to get the cooling system and *hopefully* A/C system to fit and operate.
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Old 11-16-2019, 05:48 PM   #4
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

For the engine management I'm using a Link G4+ WRX104+ plug-in ECU.



After studying the ECU pinouts, Forester wiring harness, and EG33 engine harness wiring diagrams, I've managed to wire the EG into the Forester harness using all the existing wiring.

Since the Link G4+ drops in the stock ECU case everything on the inside pretty much looks OEM



The few exposed wires are for external sensors and switches that I'm adding into the Link.

On the engine bay side, I took OEM connectors from the EJ253 and OEM car side connectors from the EG33 and made a "Plug and Play" engine harness.





This allows me to keep the car side of the wiring intact with all the necessary "conversion" happening in the PnP harness. This also gives me the provisions for the SVX igniter since the EG33 uses "dumb" coils with no internal igniter.
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Old 11-17-2019, 12:14 AM   #5
JDMJNKY
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MURK'D

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so far, so cool!
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Old 11-17-2019, 07:00 PM   #6
S2 13BT
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Location: Canberra, Aus
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2006 Forester XT
Obsidian Black Pearl

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Awesome!

I really wanna do an EZ30 into my XT. This is motivational!
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Old 11-18-2019, 03:42 PM   #7
CursezZz
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Location: Baltimore
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2006 Subaru WRX STi
Obsidian Black Pearl

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bump for paystub photo XD
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Old 11-20-2019, 09:54 AM   #8
96accord
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Location: Middle River, Maryland
Vehicle:
2007 Impreza WRX STi
'15 Accord (Daily)

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Subscribed.
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Old 11-20-2019, 11:51 PM   #9
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Started working on getting the radiator to fit today.

I am using a Northern Radiator universal fit 70s Ford/Mopar 2row crossflow radiator. It has the inlet/outlet in the proper locations and has 1.5 inch in/out as needed.



It fits pretty well for a radiator that was never designed to fit here! I have to make an additional mount for it then I can move onto custom hoses.


Fits with the bumper and beam installed no problems.


I have a JDM grille that's been sitting around and now I'm putting it to use. The radiator kind of forced my hand as the original grille won't come close to fitting. The JDM grille doesn't fit the best with usdm bumper and headlight surrounds but it'll do for now.
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Old 11-26-2019, 12:35 AM   #10
wuuusaa
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Location: Lane splitting in Cali.
Vehicle:
2015 Wrx

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I honestly never really cared for the H6 motors until I saw the guys from mightcarmods super gramps build. Totally changed my out look for sure haha.

They sound amazing with a proper built equal length header especially with a turbo in the mix.

Overall what is the end goal with the car? 9's as a DD?

Is that the GC that got peeping in the back ground?
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Old 11-26-2019, 12:04 PM   #11
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Quote:
Originally Posted by wuuusaa View Post
I honestly never really cared for the H6 motors until I saw the guys from mightcarmods super gramps build. Totally changed my out look for sure haha.

They sound amazing with a proper built equal length header especially with a turbo in the mix.

Overall what is the end goal with the car? 9's as a DD?

Is that the GC that got peeping in the back ground?
I don't have a concrete goal for the car, I just wanted a fun project that's going to be fast

Yeah that coupe is my other car, most of the damage is underside and inner structure 😢
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Old 12-03-2019, 09:25 PM   #12
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Bought a universal fit mini A/C condenser so i could have some sort of working A/C next year, definitely not expecting the efficiency of the OEM system, but some cooling is better than none at all.



Fit that up and ordered the pieces needed for me to make custom A/C lines where needed to connect to the rest of the stock system.

Also got my treadstone intercooler mounted up, grille and all still fits so thats a win!



Working on devising a plan for air shrouding behind the bumper to force all of the air coming thru the opening thru the intercooler, condenser, radiator to maximise the efficiency.

More to come soon.
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Old 12-04-2019, 03:03 PM   #13
lub
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Location: Virginia
Vehicle:
2004 WRX wagon
Blue

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Can't wait to see this thing finished!
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Old 12-30-2019, 10:02 PM   #14
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Got the EG started on Saturday!

After some playing around with the inital fueling I finally got the engine to fire up and run! it idles great, but I only ran it for 15-20 seconds since I don't have the cooling system finished yet. The other guys in my shop were pretty excited too lol, can hear them comment in the video

Making progress! Excited!


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Old 12-30-2019, 10:15 PM   #15
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Also on Saturday I deleted the ABS and Hill holder from the Forester.

I removed the main brake pipe assembly and replaced with a new OEM brake pipe from a 2002 Impreza 2.5TS (non ABS) part number 26510FE030.

The GD impreza brake lines fit perfectly on the SG Forester firewall and install just like they were meant to be there! I ordered a new OEM non-ABS brake master cylinder (part number 26401FC011), should be here in a few days then the non-ABS conversion will be complete.

I also had to install a throttle cable since 05 switched to drive by wire, so I measured and drilled the firewall right where the throttle cable was on 04 and older SG foresters. While installing the DBC accelerator pedal i noticed the bolt holes for the DBC pedal were there just not threaded. A quick run with a M8X1.25 tap gave me threads and made the install super easy!

Ripped out the stock lines and ABS pump


New OEM hardlines installed, and throttle cable installed.
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Old 12-31-2019, 12:28 AM   #16
JDMJNKY
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Join Date: Jul 2010
Chapter/Region: SCIC
Location: sOuL-CaLiFoRnIa
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02 RSTI
MURK'D

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wicked sounds mon, wicked! I know I could google but would you happen to know the weight increase with this swap?
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Old 12-31-2019, 12:32 AM   #17
carnz-pj-410
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Join Date: Mar 2006
Chapter/Region: MAIC
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1995 Turbo Impreza
EG33 05 Forester

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I am not sure of the weight differences, i have not looked into it.
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Old 12-31-2019, 12:46 AM   #18
JDMJNKY
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Join Date: Jul 2010
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02 RSTI
MURK'D

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changes nothing, still bad ass lol.

Edit: EG33 weighs in at 402 and the ej257 at 410lbs in full trim

Last edited by JDMJNKY; 12-31-2019 at 04:25 AM. Reason: I had to look into it hehe
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Old 01-13-2020, 11:21 PM   #19
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Only took two photos Saturday ( was busy focused on working on the car )

Made some progress on the car though...

Swapped in my 04 STi steering rack and solid steering joint

Installed turbo crossmember and Aluminati solid engine mounts

Installed ARP extended wheel studs

Installed front brembos from my other car






Planning to get some more done this coming weekend (STi aluminum front control arms with ALK, Alignment, cooling system finalization, sensor installs, etc..)
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Old 01-13-2020, 11:47 PM   #20
JDMJNKY
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Member#: 253498
Join Date: Jul 2010
Chapter/Region: SCIC
Location: sOuL-CaLiFoRnIa
Vehicle:
02 RSTI
MURK'D

Default

Man I was watching videos of this swap after our last convo, sweet christmas, I'm excited for you. Those updates are looking nice as well.
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Old 01-14-2020, 05:28 PM   #21
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

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Are you planing to turbo it ?
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Old 01-14-2020, 07:07 PM   #22
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Yes, using a Borg Warner T4 S372SX-E

110lb/min
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Old 01-14-2020, 10:08 PM   #23
D-Rodman
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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

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Subscribed!
Canít wait to see more.
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Old 01-18-2020, 04:46 PM   #24
carnz-pj-410
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Member#: 110994
Join Date: Mar 2006
Chapter/Region: MAIC
Location: BALTIMORE
Vehicle:
1995 Turbo Impreza
EG33 05 Forester

Default

Overhauled then installed my 2005 STi aluminum control arms today

They had plenty of grime on them, the forward bushings were noisy, and the ball joint boots were shot.



Knocked out the ball joints, pressed out the forward bushings and unbolted the rears



Gave the arms some wirebrushing and de-greasing to make them look nice again

Installed Powerflex forward bushings, Whiteline KCA359 Anti-Lift Kit, and new OEM ball joints with new hardware.





Front suspension is all good now, just need to do an alignment next time at the shop

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