My 2002 WRX to EJ257 Swap!

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user098123

Active member
Alright so this is somewhat of a /claim thread, and also I know a lot of people on here are interested in Subaru's and WRX/STi's and all that good stuff. This is what is known on most auto forums as a "Build Thread"

Basically a couple of months ago my A/C Idler pulley failed while I was driving...it ended up seizing, snapping off and shredding in to my timing belt cover. This caused my belt to shred, skip teeth and then my pistons hit all of my valves. Nothing like catastrophic engine failure in your beloved car to end your summer.

So, where does that leave us? Decided that I was going to do what is known as a Hybrid swap. I am getting pretty proficient with engines, and decided this would be my best bet. So, I contacted Ron at Raw Performance in St. Louis and using my old 2.0L EJ20 WRX heads he built me a longblock containing a EJ257 2.5L STi shortblock. So essentially I am running an STi engine with no AVCS and a slightly smaller head combustion chamber. This is remedied though by an increase in compression ratio.

Well I just got the car back, and it is FAST! It pulls hard, despite only having mostly stock WRX parts. Right now I am probably pushing about 325-350 bhp, once I get done breaking in my new engine and do some OpenSource Tuning and see where I am at. Below are my current mods and future mods, as well as my long term goals:

Hybrid EJ257/EJ205 Head Swap with +1mm Oversized Valves

Lightened Unorthodox Racing Pulley

Iridium Plugs

Cobb Downpipe

Borla Hush Catback Exhuast

Grimmspeed Ceramic Coated Catless Uppipe

Snorkus Delete and Modded Intake

Grimmspeed Thermometer

Opensource Tuning with Wideband O2

To Do:

Fuel Injectors

Walbro Fuel Pump

Blouch 18G-TD05 8cm^2

Grimmspeed EBCS

Tranny Cooler

Valvebody Modification

Front Mount Intercooler

TGV Deletes

Phenolic Spacers

Target Power: 350 whp(450-475 bhp)/330 wtq

Currently saving up for Injectors, Fuel Pump, EBCS, VF39 and that will hold me off until the Blouch 18G, which is a pretty big turbo and will really up the power.

So without further ado, some pictures for anyone who is interested:

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Needs cleaning haha...

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Notice the shiny block and timing belt cover!

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Tuning and logging OpenSource with ECUFlash and RomRaider.

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Old engine, going to be split and rebuilt. I will then swap this shortblock in to a GC8 (1999-2001 RS) body and turn it in to a track car.

Anyway if anyone has any thoughts, suggestions or comments feel free to post! Hope you enjoy and I will keep this thread updated as I continue the build!
 
so sick! wish i had an imprezzie, but until then, 99 4runner yeaa.
wanna race?
 
dope, i know this guy who races bmw's on the track, he has a killer '99 3 series, thing sounds like a suby but im pretty sure its faster, wouldnt do well off road, but he has the engine built as shit, things beat though, got 2 replacement panels on it, 3 of the original rims and 1 oz racing rim, and a back seat tear out, hes 26 or so and its not a piece of shit, just not worth making it look all pretty lol
 
Unless you are getting ridiculous drivetrain loss (like 25%+), you won't need 450bhp to get the numbers you want. Sick idea though, and definitely a realistic goal as far as HP and TQ are concerned.
 
Ya I need wheels, but I can't afford it right now. I am literally broke haha...this whole swap has cost me about 4k. I am thinking of painting them gunmetal, there are some good threads on how to do it

I could go GT35R...but that would require rotated turbo and probably a front mount and I don't want to have the throttle lag from a FMIC nor go with the headache of going rotated.
 
You do get about 25% drivetrain loss so people say. The AWD setup really saps some of the power...gives you huge potential and feels like way more than what it puts down on the Dyno but the numbers come out to be less.

I am also running the 4EAT...which is actually the best transmission that Subaru ever made and some of its setup is what is in the WRC cars. I am going to beef it up a bit and keep it for now cause of its ability to move around torque and then do a 6 speed STi MT swap. I couldn't find a WRX with a MT when I bought one and the 4EAT is WAY WAY better than the WRX 5MT which is a pos transmission.
 
Haha I know they are super legit looking...but they come with a big throttle lag...not the same as turbo lag, it is more in the pedal. The reason I am going with the 18G is cause it has a lot of power, and it will spool up crazy fast on the EJ257 shortblock. That way I will have a really fast car from the line and for Auto-X and stuff...it lacks some top end, but I am ok with that because I won't be doing dragging really anyways.

I do want Mudflaps..but they are another $125 that I can spend on other upgrades first.
 
Hmm... that is true. Have you ever thought about a centrifugal blower? They are a bit pricey but if you are serious about Auto-X it may be the way to go because they have zero lag. I know Jackson Racing makes some really nice ones.
 
No I haven't looked in to them...I haven't really heard of many Suby guys running them but maybe I'm just missing those topics. I will do some research.

Ya my plan is to go with a VF39 swap and fuel upgrades (STi turbo but I will push a little more power until I can get my bigger turbo and then do a 6MT. If I do the valve-body mod to my Auto it should be good for a while though. They can hold some pretty serious power if done right.

There is a guy running mid-9's in the 1/4 on his automatic.
 
Ya they can be pretty bad...but when you get in there it is actually much simpler than it looks. There are a couple big tanks and the intake and stuff that just take up huge amounts of room. When you get around those though it isn't bad except for around the bottom of the intake manifold.
 
Interestingly enough Ken Block doesn't even run a GT35R in some of his STi's because of the decreased turbo spool. He opts for the GT30R.
 
thats cool. anything cars just runs right over my head, but i like to think when im PAIDDD i could get into that shit.
 
anyone can buy a car, for real enthusiasts the fun comes from doing the research and building how you want. You sound like you know your subbys quit well. Id like to do up a WRX one of these days, if the extra money ever comes haha. Keep up the good work with your car man, there will always be people who can appreciate a car to its full potential. i think +k just cause you sparked my interest in subaru again.
 
An STi would have blown out just how my WRX did...wasn't interested in a STi anyway, my WRX is as fast as a stock STi right now, and when I'm done with it, it will be leaps and bounds ahead. I wanted a car that I could learn to work on, and the WRX is perfect for that. I really do love this car, or else I would have scrapped it when I blew the engine. Now I have a higher performance platform to work on.(though..the 2.0L WRX block is actually stronger than a 2.5L STi block because of how they add the displacement to the 2.5L. Hence why I am going to rebuild my WRX block for a high-rpm scenario, rev-limit at like 9k)
 
So between working and class I have been tearing down my old EJ205 block. More pics to come soon hopefully, but this is a slight progress report. If you look at the pistons you can see where the valves met the pistons and bent, giving me all the problems in the first place.

Once I save up some money I am going to be boring it out a little bit, checking all the clearances at a machine shop and then throwing in some CP pistons and Eagle rods I am thinking as well as some ACL race bearings. Then I just have to save up for some heads and a GC8 body as well as some more parts that I can build a car out of. Hopefully that will come in a year or so.

Anyway, if anyone is interested here is what your Subaru engine looks like torn down:

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It begins, on the kitchen table! Notice the roommates Head skis in the background.

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More parts off, you can see my retarded bolt template in the background as well as the oil and water pump.

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Pistons coming out, not the most organized way to work. However, as long as I know where the bolts go that is all that matters. I am getting rid of the rods/pins/pistons for new internals.

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Two pistons out, these things are IMPOSSIBLE to get out in an EJ20. Have to remove all the pins to split the block, not necessary to get all the pistons out.

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Block split, finally! Nice looking crankshaft, rods still have to come off.

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Pistons out, you can see where all the damage was done.

Anyway that is where I am at for now, hope it is somewhat entertaining! Rods will be off soon as well as bearings and then it is off to the machine shop to be hot tanked and have the clearances checked.

As for the WRX, hoping to get a couple of parts for Xmas.

- 850cc Deatschwerks (sp?) Injectors

- Walbro Fuel Pump

- Grimmspeed EBCS

That should allow me to run my TD04 to max capacity until I can get a better IC and turbo etc to really get me up there in numbers!

Stay tuned (no pun intended) for more!
 
Ya I would like to find a 2000 RS with a blown engine if I can which is what this block will be going in to. I am going for a high rev engine, looking at hopefully like 9k rpms. Should be a beast.
 
I just bought a complete EJ257 block, not sure if I'll get around to doing anything with it anytime soon, but I'm planning on doing something similar. Looks good!
 
this is part where i kinda agree, although you've had your fair share with our e85 argument along with a few others.

i am a fan of the build though.
 
We will take a moment in this e-battle to bring you a non-sarcastic comment from Jawflyer3

"dude, good work. Looks like you know what you are doing and I wish you the best of luck on your rebuild. WRX's are dope stuff, i am jealous"
 
hahha your a joke! for your things to do's should be either straight cut gears a flywheel and clutch... or a six speed swap..i blew my 5 speed on stage 2 soo if u drive anything like me and plan on doing anything u explaining you will need a better drive train....... plan on busting axels too .. i blew some with a ported 39 on my wrx sti conversion... if u have this power output that u plan on having... upgrade ur brakes to some 2 pot 4 pot's or better unless u dont think stopping is necessary. Also will need a aftermarket turbo inlet if that wasnt on the list.. i didnt look.. u will not need to do tgv delets with a 18g unless youd perfer it.. and also smarty u shouldnt get a fmic unless u run a 20 g or bigger because a 18g will not use up the full potential of the fmic soo its a waste of ur money buy a big tmic.. and if u wanna get a 39 just to "hold" u over till u get ur 18g u better get injectors also and a bigger tmic or its a waste of ur money even putting that vf39 on ur car.... then buy more injectors when u get the 18g. i think its funny that u thought thati didnt know what meth injection did

your obviously a nasioc thread junkie.. dont listen to what ppl say on there
 
Yes, please don't listen to anything on NASIOC. Instead, take technical advice from someone who seems to find the basics of the English language just a little too complicated. It's called a period buddy, you only need one at a time.

Coming from a fellow '02 WRX owner, fucking sick project, good luck.
 
Cool? I know what I am doing and I am doing it exactly how I want to. Yes it is an auto, couldn't find a manual at the time. I know the limitations of an Auto and have it planned out with what I want to do. If you notice the to do list it is engine parts, not suspension or braking or driveline for now. I actually am not a NASIOC thread junkie, go figure, I rarely post there and use it mostly for some info.

Did I say I was going FMIC? No, I said maybe, but I am going TMIC. What is my next upgrade? Injectors...hmm you clearly don't know how to read.

You obviously didn't read anything I posted at all and sorry I don't have infinite amounts of cash being a starving college student.
 
Sorry I did say FMIC in the original post but that is no longer the plans. Anyway, I could really care less what you have to say on my project Parkbumm.
 
im not trying to be a ass about it....just dont listen to what ppl say on subi sites

i have a ported 39 and injectors and a tmic for sale
 
im doing a 18g with a fmic :(

he's right about transmission. that things gonna take a shit all over the place with a 2.5
 
ull just get a little more lag.. the way he's talking he wants to do auto x and stuff. you dont want lag for that.. no worries!
 
Not necessarily. The Auto transmission is much stronger than the 5 speed manual. Upgrade the valve body and get an oil cooler and it can last really far. The advantage of the Auto transmission in the WRX is that it has the best AWD system of any Subaru, better than the STi.

There is a guy with a slightly rebuilt Auto transmission running 9.5 second quarter miles, so it can definitely hold its own.

As for the other suggestion, going straight cut gears is just stupid. You can't even drive a car like that without headphones to block the noise. An 18G with all PnP upgrades, new headers, etc, will not spool at 3k rpm's, more like 3.5k rpms, but it will hit very well.

A FMIC does nothing for turbo lag. It will still spool up at the same RPMs. What you notice with a FMIC is Throttle lag, which is different. It isn't a huge deal, but some people don't like it. An 18G is also not too small for a FMIC, but it is borderline. It depends if you need the superior cooling or not depending on your climate and average air temp. Because you are on NS I assume you are in a cooler climate so you can either go cheap FMIC or big TMIC and be more than fine.
 
Also I am sure you know this but just to reiterate it, if you go with Equal length headers you will lose the "boxer rumble" that a lot of people love.
 
the auto transmission is not stronger then the sti six speed

manual..... and u have to spend alot of money to make that auto nearly

as strong as a sti six speed

its proven that fmic create lag... i personally know that it does and unless u buy a fmic where the core doesnt over come the turbo then u wont have lag as bad..... 18 g will have lag im sorry to tell u grunner...but lag is awesome.. i love it on my carmine hits at like 3900 maybe a little less but i have a lighter flywheel, ported headers a up pipe and a 3 piece pulley set...soo i may have gotten rid of some lag

u have a tmic still soo untill you get a fmic u wont know..

you will loose the boxer rumble but u will have much greater flow... or you could buy a set of ported stock headers

and auto's have less potential at the drag strip as a manual. and no where near as fun to drive
 
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