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Old 05-15-2014, 02:16 PM   #1
slowgenius
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WRX 03/04/07 hybrid
PSM

Default 04 WRX build and swap

**Updated with most recent progress**

Thanks for stopping by. This thread is a summary of a project I have been working on the past several years. It is a 2004 Wrx i purchased new in 2003. I ran it stage 2 until 2009 when it spun a bearing.

Way back in 2004







I had been working with Moore Performance, a great local shop since 2010 for most of my parts and some of the work that has gone in to the project.

They built a complete EJ257 for me early on.

I picked up a wrecked 07 wrx with 62k miles with front end damage for parts.

I also picked a v7 six speed swap from a local guy.

Ill keep this thread updated with my progress and pictures.

04 WRX





07 WRX



What i have so far.

Engine

Ej255 longblock from 07


Koyo racing radiator

Transmission

6 speed v7 sti (non dccd)
ACT flywheel and sprung 6 puck clutch


Exhaust

AP UEL Header
TurboXs catless up pipe
Godspeed catless down pipe
SpecD Tuning cat back exhaust

Turbo

VF 43
Treadstone front mount intercooler

Fuel

Walbro 255

Electrical

Grimmspeed EBCS
Turbo Smart MBC
Autometer boost
Autometer Egt
Autometer electronic fuel pressure
Autometer oil temp
Autometer oil pressure

Brakes

Front Subaru 4 pot
Dba 4000
Rear Brembos
Goodrich braided stainless hoses

I decided to swap the entire electrical system from the donor car, along with the engine and interior.

A few of the comments following my original post may be regarded as typical nonsense.
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Last edited by slowgenius; 10-03-2019 at 02:13 AM.
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Old 05-18-2014, 10:16 AM   #2
DHRDAN
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01 2.5RS W/ EJ257
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Default

oh geessss.... so many questions.

1. Why did you spin the bearing? at 72K... if that's the mileage (but i can't tell because you suck at sentences) that is very very early. Run the wrong oil?



2. If you have a 07 it will swap in with the ECU+key+immobilizer. If you don't' have the ECU, you can't run the same heads because the 07 has dual AVCS and the wrx does not.


3. You have a VERSION 7 STI SIX SPEED???????? Where did you get that??? That might be worth a bit. Though a jdm version 7 transmission into a USDM car will need to have the proper wiring. I never heard of a version 7 transmission being put in a version 8 wrx. There would be no point, you would make more money parting it, though that would take time.
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Old 05-18-2014, 04:25 PM   #3
slowgenius
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The six speed swap i purchased off a local guy who had it in his 09 wrx. His car was totaled so i got it to match up with the engine i built.

Its a non dccd jdm six speed, matching R180 diff. with rear Brembos, and front Subaru 4 pots. 5x100 bolt pattern all around. As far as i know the v8 six speed is dccd.

The 07 wrx i bought is the whole car minus a fender and some of the front bumper and headlight. It has mostly everthing i need.

Last edited by slowgenius; 07-16-2015 at 12:16 PM.
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Old 05-18-2014, 04:42 PM   #4
slowgenius
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Updated

Last edited by slowgenius; 04-10-2015 at 09:21 AM.
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Old 05-19-2014, 02:21 PM   #5
slowgenius
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Donor car is supposed to ship today, and arrive tomorrow.

Last edited by slowgenius; 06-22-2014 at 01:32 AM.
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Old 05-20-2014, 06:15 PM   #6
slowgenius
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Car showed up today. I should get away with just replacing 1 cam gear and couple valves. I was hoping that wouldnt be the case but all in all i will be able to recover most of what i will have in it.

Added pics to first post.

Purchased used heads to swap out.

Last edited by slowgenius; 06-22-2014 at 01:35 AM.
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Old 06-06-2014, 12:20 PM   #7
slowgenius
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Heads are in, waiting one cam gear and gaskets.

Last edited by slowgenius; 06-22-2014 at 02:11 AM.
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Old 06-13-2014, 07:04 PM   #8
wreckedj30
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Quote:
Originally Posted by DHRDAN View Post
2. If you have a 07 it will swap in with the ECU+key+immobilizer. If you don't' have the ECU, you can't run the same heads because the 07 has dual AVCS and the wrx does not.
What 07 has dual avcs? Sti didn't get it until 08 in the US. Also 08+ you can always leave the exhaust avcs connector unplugged and it'll work just fine.

You can use the ej255 from the 07 in your 04wrx without a head swap, your just going to need to swap a few connectors and add some grounds to the cam position, coolant temp sensor. Also use the 04 intake or your going to deal with the dbw instead of dbc. Then get a tune for the .5 displacement added.

If you want to do the wiring swap from 07 to the 04, your going to need the dash and engine harness and splice in a few connectors; headlight etc. Then add the dbw pedal assembly, the abs module, smog pump. etc.

As for the transmission bolt in and go as long as the final ratio is the same or your using the matching differential.
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Old 06-13-2014, 08:01 PM   #9
slowgenius
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Quote:
Originally Posted by wreckedj30 View Post

What 07 has dual avcs? Sti didn't get it until 08 in the US. Also 08+ you can always leave the exhaust avcs connector unplugged and it'll work just fine.

You can use the ej255 from the 07 in your 04wrx without a head swap, your just going to need to swap a few connectors and add some grounds to the cam position, coolant temp sensor. Also use the 04 intake or your going to deal with the dbw instead of dbc. Then get a tune for the .5 displacement added.

If you want to do the wiring swap from 07 to the 04, your going to need the dash and engine harness and splice in a few connectors; headlight etc. Then add the dbw pedal assembly, the abs module, smog pump. etc.

As for the transmission bolt in and go as long as the final ratio is the same or your using the matching differential.
Were you asking something? I have a whole 07 wrx to swap everything out of. The chassis is no good.

I am waiting for my cam gear and gasket set to come in. I should be able to fix the engine end of next week. I am going to start the interior swap monday.
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Old 06-15-2014, 04:46 PM   #10
wreckedj30
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No I wasn't asking anything just defending you from dhr whatever. It's a simple swap straight forward. Just use all the wiring ecu and engine and your golden.
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Old 06-15-2014, 05:11 PM   #11
slowgenius
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Quote:
Originally Posted by wreckedj30 View Post
No I wasn't asking anything just defending you from dhr whatever. It's a simple swap straight forward. Just use all the wiring ecu and engine and your golden.
Haha thanks. My biggest issue is swapping the dbw pedal over. I found a company that used to make a bracket but they were out of stock on it.

Last edited by slowgenius; 07-16-2015 at 12:58 PM.
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Old 06-19-2014, 06:55 PM   #12
slowgenius
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Updated

Last edited by slowgenius; 06-16-2019 at 02:20 AM.
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Old 06-21-2014, 11:45 PM   #13
slowgenius
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Updated

Last edited by slowgenius; 04-10-2015 at 09:23 AM.
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Old 06-23-2014, 10:04 PM   #14
slowgenius
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Gaskets and timing stuff came in today.
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Old 04-07-2015, 09:37 PM   #15
slowgenius
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Long overdue update:

I pulled the engine and transmission from the 07 wrx.





I will work on preparing it for use. I have some cleaned up used heads to put on it along with a new cam gear, timimg belt, water pump, and pulleys.

Once the engine is complete, i can begin to install the wiring harness and ecu.

Last edited by slowgenius; 07-16-2015 at 12:56 PM.
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Old 04-07-2015, 09:43 PM   #16
slowgenius
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Updated

Last edited by slowgenius; 06-16-2019 at 02:22 AM.
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Old 04-07-2015, 11:29 PM   #17
Bikelok
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I'd rethink the oil and change interval. This might be why you spun the bearing so early.

A more robust oil and a longer interval between changes might help. That 5w-30 oil is probably shearing and you change it to soon before the additives really get to do their thing even if it's not thinned out by then.

I think it will be a very cool build when it's all done.
Keep us posted.
Good luck
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Old 04-08-2015, 11:04 AM   #18
slowgenius
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I put 50k miles on the engine with the TurboXs stage 3 setup way back in 2004. I appreciate the advice, and the interest. Believe me i know alot more now than i did back then.

Last edited by slowgenius; 06-24-2016 at 10:07 PM.
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Old 04-29-2015, 02:49 PM   #19
slowgenius
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Intercooler came in yesterday. Cleaned out garage and have both engines in there now.
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Old 06-22-2015, 10:53 PM   #20
slowgenius
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The ej255 is being repaired this week, i removed all non essential bits while the heads are being swapped. Its getting new belts pulleys and water pump.

Last week i recieved a new catless up pipe, and catless turbo back exhaust that will go on when the engine is done.

I ordered a new trasmission mount for the six speed, and new crossmember bushings.

Last edited by slowgenius; 06-22-2015 at 11:03 PM.
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Old 06-28-2015, 10:39 PM   #21
slowgenius
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I started removing the seats, carpet, dash board, hvac, steering column, airbags, and dash beam in the 04 wrx to make room for the wiring, ecu and interior from the 07 wrx.





I wil call tomorrow to see how far along the engine is comming.

While the interior is stripped, hopefully i can run the larger fuel lines and extra power to the trunk for the fuel system and possibly an amp for the stereo system.

Last edited by slowgenius; 07-16-2015 at 12:46 PM.
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Old 07-01-2015, 07:52 AM   #22
slowgenius
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Talked to the shop, the engine may be done this week. Friday?

There is a local monthly meet around here today so i am dropping my header and up pipe off to get coated and grab a few brews.

I havent done anyyhing since sunday with all the rain we have been having. The next few days im off work and rain or shine, i want to have all the wiring out of the 04, and most of the 07 wiring and interior back in.

Yesterday i ordered some aluminum piping to make a hard turbo inlet pipe, a 3 to 2.5 inch silicone reducer, and the SPT intake and cone filter.

Last edited by slowgenius; 07-01-2015 at 08:03 AM.
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Old 07-05-2015, 12:07 AM   #23
slowgenius
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Spent last few days stripping the car down. Front fenders and bumpers are off.


I got the two main wiring harnesses out of the front half of the car.

The steering wheel and coulmn are out. The seats, dash, carpet, ecu, fuse panel, dash beam and airbags. The hvac, cruise actuator and ABS solenoid also removed. I also pulled the passenger side door harness to change over to heated mirrors.

Discharge the A/C system before you take out the heater core and cool unit inside or you will have a mess.

I cut out the front of the lower radiator support to make room for the treadstone intercooler. I welded a plate over what i cut out to strengthen it. Ill grind and paint it tommorrow, then mount the intercooler hopefully.

As far as pictures i have plenty of them, when i get around to it ill update my posts with them.

Last edited by slowgenius; 07-14-2015 at 02:27 AM.
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Old 07-08-2015, 10:26 PM   #24
slowgenius
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Almost done removing old harness.

Last edited by slowgenius; 07-08-2015 at 10:38 PM.
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Old 07-08-2015, 10:27 PM   #25
slowgenius
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I am obviously not a professional welder.

Last edited by slowgenius; 07-16-2015 at 01:05 PM.
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