Rosssub's Single Turbo Conversion.

[Rosssub]

I was going to drill new 1.5mm holes for the high and low mark, then dremel the max hot/overfill notch.

P/N 11140AA120 Standard dipstick

P/N 11140AA150 T/S dipstick

P/N 15144AA011 Tube (identical)

Edited May 31, 2014 by Rosssub

[Rosssub]

I was originally thinking I would reshape the original VF27 turbo bracket, for the VF36. But after a trial fit I think I'll just find an original twin scroll bracket.

 

Here's a single scroll WRX bracket fitted:

 

The twin scroll flange sits 30mm lower:

 

My original VF27 bracket fitted:

 

Even bigger height difference:

 

Also both look much heavier than the twin scroll bracket:

 

VF36/VF37 Turbo Bracket, OEM p/n 14421AA091:

 

[Rosssub]

Manifold trial fit, checking pipes, clearances etc:

 

Original BH engine loom cleaned, checked and re-taped:

 

Loom installed, I've relocated my purge control solenoid into the BBOD, (instead of front of manifold).:

 

Manifold on:

 

[Jono24]

Have ya got a bracket on that turbo yet?

[Rosssub]

 Jono24 said:

Have ya got a bracket on that turbo yet?

Nah not yet, trying to find an OEM T/S bracket.

[Rosssub]

The version 7 GDB/GDB manifold/header tank mounting point, is 20mm higher than the BH/V5/V6 header tank. So the GDB header tank hoses I'm using were almost kinked when installed. So I've painted some 10mm spacers (big nuts) to raise the GDB header tank slightly when on the BH manifold, then used longer bolts. The 32mm stainless pipe bend is for my BOV recirc:

 

GDB header tank/GDB bottom hose installed, with 10mm spacers fitted:

 

Top V7 header tank hose in. Original BH drivers side TMIC mounting bracket back in:

 

32mm stainless bend, painted and fitted into my original BH TT BOV recirc hose:

 

TMIC back in:

 

 

BOV recirc now ready for a straight length of hose to the new version 6 intake pipe:

 

Now I just need a turbo mounting bracket and a few lengths of black silicone/rubber hose, for the BOV recirc and engine breather pipes/catch can:

[94 Leone]

So, you're not going split fuel rail with this manifold/side feeds?

[Rosssub]

 94 Leone said:

So, you're not going split fuel rail with this manifold/side feeds?

Nah, will do it when the version 7 manifold/baby blues go in. I couldn't warrant the extra expense just for engine break in, (temporary measures). I've got 2 sets of version 7 fuel rails/lines here ready to go.

[Jono24]

Did you reuse the tt bov or a different one?

[Rosssub]

 Jono24 said:

Did you reuse the tt bov or a different one?

Reusing the original in the photos.

[Rosssub]

I've ordered a new dipstick from Subaru, $29+gst. With a 7-10 day wait coming from Japan. I'll put measurements up when it arrives. I set the engine breathers up yesterday, just using 1/2" Dayco heater hose from BNT for now.

 

Right bank head breather running over the turbo inlet, then straight across the back of the manifold to a T-junction at the other side:

 

I finally got around to blocking off my PCV valve properly, with a 1/2"npt bung from hose & hydraulics:

 

With the PCV blocked off, I've run my main block breather vertically straight into the intake. I will Tee the smaller block breather into the head breather hose above it, just need another T-junction:

 

I've reused half of an original BH head breather hose on the left head, running to the T-junction just inside the manifold runner:

 

Both head breathers T'ed together, then run under the manifold to the front intake pipe breather port:

[Rosssub]

This pic is showing the TT heater pipes, under the TMIC. With the STI y-pipe on, the drivers side heater hose has no room. The original BH firewall heater hose will be kinked and rubbing on the y-pipe:

 

It will also make fitting/removing the TMIC a PITA and still be in the way once the version 7 STI manifold/TMIC go on:

 

The version 5/6/7 run one of the hard lines sideways towards the left bank head, leaving clear space for the STI y-pipe. Here's a GDA heater pipe I'm thinking about swapping over:

[94 Leone]

^Rossub; that is the engine I'm going to buy haha. As soon as I have my refund... taking far longer than expected.

[Rosssub]

 94 Leone said:

^Rossub; that is the engine I'm going to buy haha. As soon as I have my refund... taking far longer than expected.

Sweet, that'll be a fast easy fit. Yours will be running before mine too.

[Rosssub]

Before: (BH heater hard line)

 

After: (V7 heater hard line)

 

[Rosssub]

While waiting for parts and the manifold was off. I've painted and installed the version 7 block coolant crossover pipe.

 

Version 5/6 STI: (uses the smaller temp sensor for the dash temp gauge)

 

Version 7 WRX/STI:

[94 Leone]

That also means; you get to use you BH Radiator Hoses; you might want to check to see if the thermostat housing one will match your lower radiator hose too. as radiators have different inlet/outlet with GC/BG vs GD/BH

[GC82GO]

Looking at your photos makes me wanna take my motor out and clean It, nice motor build man...

[Rosssub]

Quote

My original BH5B top hose/alloy pipe was the same as the version 5/6, with the angled front. Now I'll have to fit the GDA/GDB top radiator hose, (less of a bend in top hose). Bottom outlet/hose stays the same.

 

On ‎8‎/‎06‎/‎2014 at 10:42 PM, GC82GO said:

Looking at your photos makes me wanna take my motor out and clean It, nice motor build man...

Thanks GC82GO, it's taking so long I ran out of parts to clean up.

[94 Leone]

really? odd; I thought mine was straight(just checked pictures, it isn't) ; as I'd bought Silicone radiator hoses for a GC8(a while ago) but they didn't match up properly assumed BH had simply used GD style radiator changes...

[Rosssub]

Yeah the only change BH-GD is that where the top hose meets the block. I figure with the water doing less of a turn at higher rpm, less stress on the rubber radiator hose.

[Rosssub]

Another piece to the puzzle, VF36/VF37 twin scroll turbo/up-pipe bracket. $129+gst from Subaru:

 

Fitted:

 

 

I had to reshape the VF27 oil feed again, to clear the new bracket:

[Rosssub]

To finish of the BOV recirc, I've fitted a 425mm length of 28mm I/D straight reinforced silicone hose to the new intake pipe:

 

Manifold back on with all engine breathers and BOV recirculation sorted. Also the relocated TT heater pipe:

 

The new twin scroll dipstick should be here early this week:

[Rosssub]

While working through the engine bay cleaning I've swapped the clutch master cylinders over. This is the original BH that will be jammed underneath the version 7 STI TMIC when it goes in:

 

The new version 7 STI clutch master cylinder fitted:

 

Here's the two side by side. The version 7 STI master cylinder has two hard lines running to the slave cylinder, the BH only has one. So I've blocked the front GDB port with a threaded blanking bung:

[Rosssub]

The version 6 STI J2 ECU went in this evening. I've used these ECU pinouts:

 

BE/BH rev ABC:

http://www.brdevelopments.com/docs/MY99%20Legacy%20TwinTurbo%20ECU%20pinout.pdf

 

Version 5/6 WRX/STI:

http://www.brdevelopments.com/docs/MY99ecu.pdf

 

Fuel pump relay pin moved.

 

The WRX/STI runs wasted spark with cylinders 1&2 and 3&4 firing in pairs, so only 2 pins/wires used at the ECU. The TT uses COP (coil on plug) with a separate ECU pin/wire for each cylinders coil.

 

The STI ECU boost control solenoid, uses the same pin as the BH primary boost solenoid inside the F/L guard. I want to use my ECV solenoid in the BBOD for boost control so I've swapped the pins/wires over at the ECU.

 

Here's a diagram showing the pins I've changed, using the STI diagrams plug numbers:

 

To change ECU pins, I've popped the white clamp section of the ecu plug up with a flat head screwdriver, the white section lifts about 2mm:

 

Then gripped the wire I wanted near the plug with pliers, then a sharp tug and the pin pops out. I've labelled the wires to avoid mix ups, this is all four BE/BH coil on plug ignition wires/pins removed ready for splicing:

 

Cylinder 2 coil pin cut off, then the wire exposed at the same point on cylinder 1 wire:

 

Soldered together, cylinder 1 and cylinder 2 coils now firing together, (wasted spark).

 

All four ignition coil pin/wires spliced and heat shrinked, all other pins moved:

 

STI ECU installed ready to go: