Rosssub's Single Turbo Conversion.

[megamac]

Quote

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:

Do all EJ20s have two block breathers? Also just wondering what size hose did you end up using for the head breathers?

[Guest]

 megamac said:

Do all EJ20s have two block breathers? Also just wondering what size hose did you end up using for the head breathers?

V7-.

[Rosssub]

Yeah only later model STI's from version 7 onward have the second crankcase breather port, also an extra head breather port on both rocker covers. It's to equalize pressure between the block and heads. As above I originally used 1/2 inch heater hose, then changed to 12mm silicone hose asap because coolant hose doesn't like oil.

[megamac]

Brilliant, cheers mate! Off to repco

[Rosssub]

Got hold of a version 5/6 GC8 gearbox crossmember last week so I can finally get the new DP on (cheers SAS).

 

After a good clean:

 

Disassembled:

 

Rust removed:

 

All ready for paint:

 

Then 3 coats of Chemz Zinc Black semi gloss:

[l2eeFer13]

Hey Rosssub did you replace and your seals and gaskets when you done the pistons?

If so do you have a list around with a majority of all the part numbers?

[Rosssub]

 l2eeFer13 said:

Hey Rosssub did you replace and your seals and gaskets when you done the pistons?

If so do you have a list around with a majority of all the part numbers?

Didn't need to split the block, but replaced everything else. Are you splitting the block?

[l2eeFer13]

 Rosssub said:

Didn't need to split the block, but replaced everything else. Are you splitting the block?

The block has done 170,000 so I wouldn't mind changing the bearings and whatever seals that are in their

[l2eeFer13]

I got this list from a guy selling a "complete rebuild kit" off eBay. It's about $700 shipped so I will go with partsouq

[thermos]

Ross, you're a life saver for putting all this info in one place.

I've gathered all the needed bits for this but I'm using the ej208 and running the 205 oilpan/dipstick. Doing a custom High mount TD04 19T with a 9 blade exhaust wheel and billet front..running on a Link WRXlink5/6. I'll get a thread going once it's underway. Excitement mounts.

[Rosssub]

 l2eeFer13 said:

I got this list from a guy selling a "complete rebuild kit" off eBay. It's about $700 shipped so I will go with partsouq

That list is for a V7 AVCS engine with TGV and top feed injectors, so a lot of parts you don't need.

[boon]

 thermos said:

Ross, you're a life saver for putting all this info in one place.

I've gathered all the needed bits for this but I'm using the ej208 and running the 205 oilpan/dipstick. Doing a custom High mount TD04 19T with a 9 blade exhaust wheel and billet front..running on a Link WRXlink5/6. I'll get a thread going once it's underway. Excitement mounts.

I'm intrigued, where exactly are you putting the turbo?

[thermos]

Hey Boon, my plan is to put it on the driver's side, ostensibly where the stock WRX/Forester turbo sits. I'd like to keep it close to the stock location and run a turbo blanket. I'd also like to run a top mount oil cooler where the stock IC sits, but I don't want the Oil pump to have to lift that much so I may scratch that idea.

[Guest]

 thermos said:

Hey Boon, my plan is to put it on the driver's side, ostensibly where the stock WRX/Forester turbo sits. I'd like to keep it close to the stock location and run a turbo blanket. I'd also like to run a top mount oil cooler where the stock IC sits, but I don't want the Oil pump to have to lift that much so I may scratch that idea.

Cant just import stock turbo header setup?

[thermos]

I already have one along with the lower and upper oilpan off a 205, and will use it for initial startup and positioning... But due to me making an equal length header, I want to give myself some wiggle room for the design..ie routing ic piping as short and straight as possible, and then also giving clearance to the BMC for the DP etc. I'd like to be able to access the Turbo and other things easily/clean up the bay a bit. Still in the planning stages, but trying to finalize the design so I can get going on it. I'll do initial startup on a GF8 (ver5/6) ECU running wastegate boost, then swap to the Link once I can afford the bloody thing.

Sorry for the hijack Ross.

Edited October 21, 2015 by thermos

[ap2276]

Hi Ross,

I am putting an EJ257 into a BE5 Legacy and have used the 2006 STi engine mounts but for some reason the actual engine mounts are not sitting properly on the cross member but the bolts line up etc. and can be bolted down.

Any suggestions as to why the mounts wouldn't be sitting on the cross member fully?

Also seems like the EJ257 is sitting higher and the 5 speed may not line up?

[Guest]

 ap2276 said:

Hi Ross,

I am putting an EJ257 into a BE5 Legacy and have used the 2006 STi engine mounts but for some reason the actual engine mounts are not sitting properly on the cross member but the bolts line up etc. and can be bolted down.

Any suggestions as to why the mounts wouldn't be sitting on the cross member fully?

Also seems like the EJ257 is sitting higher and the 5 speed may not line up?

Im running an ej257 with earlier mounts and 5sp box. Works perfectly. Id say the difference is in the mounts.

[Rosssub]

Yeah probably a slightly different cross member shape between the BE and 06 STI too. Can you load some pic's showing what's going on? As evowrx said, get hold of some earlier WRX/STI square mounts. Could try your original BE mounts out first too:

http://clubsub.org.nz/forum/showthread.php?40756-BH5-TT-Engine-Mounts/page2

 

Here's the new GC8 gearbox crossmember all painted up ready to go:

 

Reassembled, then a good old before and after:

 

[A_J_T]

 ap2276 said:

I am putting an EJ257 into a BE5 Legacy

Sounds reeaall goood 👌

[Rosssub]

Got the gearbox crossmember swapped over today. Here's the 2 side by side:

GC8/BH5

 

GC8/BH5

 

Then fitted, before and after pic's showing the DP clearance gained:

BH5:

 

GC8:

[ADIKT]

I didn't realise these nuts are welded to the bloody crossmember

I had a massive breaker on there trying to crack those bloody nuts. Then I tried the other end.......

[ap2276]

Finally sorted the mount issue. For reference, 06 Sti mounts fit.

[ap2276]

How did you put in your r180 Diff?

I am having issues with the r180 fitting in the rear cradle / cross member! Any advice? Also, what about the rear hubs?

[Rosssub]

Quote

How did you put in your r180 Diff?

I am having issues with the r180 fitting in the rear cradle / cross member! Any advice? Also, what about the rear hubs?

I'm still running the original BH5B R160 diff and hubs, so no help there sorry.

 

Got hold of a GC8 gearbox DP/exhaust hanger bracket, thanks again SAS:

 

Thanks to the Subaru Lego system, the BH5 already has the studs for the GC8 bracket on the rear shifter linkage mount:

 

The original secondary DP hanger bracket mounted to the side of the gearbox here:

 

New GC8 DP hanger bracket bolted up, ready for an OEM fitting VF36 DP:

 

[Rosssub]

With the new GC8 gearbox crossmember and exhaust hanger bracket fitted, the OEM version 8 STI VF36/37 downpipe is now a perfect fit in the BH5: