GCrs --> WRX Swapage: my DD/Ski Beater/rallyx machine

[dppaladino]

I figure I should let DI in on my summer long car project, and consequently the reason you haven't seen me at any nor cal rallyx's this year. The car was a 2000 RS 5spd, with a bunch of little suspension mods and some NA goodies. It took alot of abuse, 3 seasons of rallyx, and one winter in Montana before she started consuming oil and coolant. With 135k miles on the clock, I decided to WRX swap.
Some pics of the car pre-swap:
http://i111.photobucket.com/albums/n128/dtpaladino/IMG_2197.jpg

http://i111.photobucket.com/albums/n128/dtpaladino/Vallejo%20Rallyx%20and%20Emporer%20Evo%20Meet/_MG_7848.jpg

http://i111.photobucket.com/albums/n128/dtpaladino/Beartooth%20Burn%20Zone/MordorSubaruHDRaru.png

http://i111.photobucket.com/albums/n128/dtpaladino/Brackett%20Creek/P1010306.jpg

http://i111.photobucket.com/albums/n128/dtpaladino/Brackett%20Creek/WindowsPhotoGalleryWallpaper.jpg
Swap details and pictures in next post

[dppaladino]

After getting outbid in several Copart online car auctions, I finally found a car for a reasonable price. The car was a bone stock 2002 WRX wagon with 79k on the clock, both airbags deployed because of a front passenger side impact. Engine started up and ran, and the car even drove fine. I decided to do a full drivetrain swap, and to have ECS merge my wiring harness's. Props to DJW Equipment for being a super helpful reseller, and for the quick cheep delivery!
Pics:
pre swap engine bay
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_2359.jpg
starting to pull the wiring harness. what am I getting myself into?
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_2363.jpg

http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_2389.jpg
engine ready to come out:
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_2394.jpg
out!
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_2413.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6152.jpg
garage
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6148.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6207.jpg
stripped
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6210.jpg

http://www.dirtyimpreza.com/forums/%5BIMG%5Dhttp://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6163.jpg%5B/IMG%5D%20%5BIMG%5Dhttp://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6164.jpg%5B/IMG%5D%20%5BIMG%5Dhttp://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6169.jpg%5B/IMG%5D%20%5BIMG%5Dhttp://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6170.jpg%5B/IMG%5D%20%5BIMG%5Dhttp://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6171.jpg%5B/IMG%5D%20%5BIMG%5Dhttp://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6172.jpg%5B/IMG%5D%20%5BIMG%5Dhttp://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6173.jpg%5B/IMG%5D

[dppaladino]

donor vehicle
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6203.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6186.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6191.jpg
WRX harness, headlights to taillights
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6189.jpg
salzalled the hell out of the front end to pull the engine+tranny out
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6227.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6229.jpg
a thing of beauty:
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6231.jpg
wheelbarrowing the rex out of the garage:
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6242.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6248.jpg

ECS should have received my wiring harness's today, I am really hoping they can get it back to me in two weeks. I took the engine/tranny to a friend who is going to check over everything on the engine, replace the timing belt, rings, and whatever else needs to be replaced.

[97ScoobyL]

Swapped GCs are the ****. enough said. haha

[573]

^^^ +1

I can't wait to see the rest of this project.

[409industries]

Swapped GCs are the ****. enough said. haha

Truer words have never been spoken. Can't wait to see the swap progress :) Good to see you posting up D.

[dppaladino]

Swapped GCs are the ****. enough said. haha

haha indeed! I'm stoked to see how the car feels when its finished. Should be pretty quick. I'm going to keep it stock for a while as I pay off my donor car.

[97ScoobyL]

Progress looks great! what all do you plan on taking from the donor?

[strat]

awesome!!

i want to do a swapped gc somewhere down the road...

[dppaladino]

Progress looks great! what all do you plan on taking from the donor?
I'm taking the entire drivetrain (radiator to rear dif) and some interior goodies (carpet, speakers, etc.) oh and wheels and tires. everything else I'm going to try and sell.

[dppaladino]

Rear end from the WRX in. Just waiting on my mechanic to give the ej20 a good overhaul. In the meantime I'm doing a bunch of detail work (pedals, carpet, engine bay goodies etc.) Just got my hands on a new clutch, Exedy Stage 1 organic, for a great price, as well as a new oil pan and radiator (both destroyed in crash). Its looking like my Subaru will have to stay in stock wrx form until I can pay off the cost of the swap next summer. My goal is to have the car mechanically sound in the next ten days. I'm still waiting on my harness from ECS, I really hope they can finish before I leave for school. Pics to come. If any NorCal people want to come help with the swap, that would be greatly appreciated. I have a shed full of stock WRX parts from my donor car that I'm looking to sell if anyone wants to come have a look!

[T-Heineken]

....I would likely be down on a weekend trip to wrench on some stuff!

When are you heading back to school?

I'm busy for the next few weekends but I might have some time!

Can't wait to see the finished project!!! I'm definitely jealous.

[em99sport]

I realize this is a budget-minded swap, but if possible, take advantage of having the engine out and score a couple of things to save yourself a headache later down the road.

Group N engine mounts-- $120ish brand new, and well worth it

catless up-pipe-- $160-200 new for a good coated one with a flex section

[dppaladino]

I realize this is a budget-minded swap, but if possible, take advantage of having the engine out and score a couple of things to save yourself a headache later down the road.

Group N engine mounts-- $120ish brand new, and well worth it

catless up-pipe-- $160-200 new for a good coated one with a flex section

I have the Group N mounts on my RS engine. I wonder if they're compatible. And why uppipe? any particular reason besides the added performance?

....I would likely be down on a weekend trip to wrench on some stuff!

When are you heading back to school?

I'm busy for the next few weekends but I might have some time!

Can't wait to see the finished project!!! I'm definitely jealous.

Thanks a lot man. I'm heading to MT for school on the 24th, I'm probably going to drop the engine in this weekend, and then spend a few days getting everything hooked up.

I talked to ECS today, and there is no way I'm getting my harness back before I leave. :unamused:
I may fly home on labor day weekend to install the harness, but I'm not even sure it will be done by then. In the meantime I'm going to try and get all the mechanical stuff finished.

[driveclimbslide]

http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_6207.jpg



Backcountry FTW! :headbang:

[em99sport]

I have the Group N mounts on my RS engine. I wonder if they're compatible. And why uppipe? any particular reason besides the added performance?

The mounts on your RS will swap over. The OE up-pipe on the EJ205 ('02-'05 WRX) has a cat in it, and they have caused problems for others by disintegrating into the turbo.

[dppaladino]

The mounts on your RS will swap over. The OE up-pipe on the EJ205 ('02-'05 WRX) has a cat in it, and they have caused problems for others by disintegrating into the turbo.

huh. I will try and find one for cheep. Theres a EGT sensor in there right? Any CEL issues with aftermarket uppipes?

After a million little delays I'm finally getting my block back from my mechanic. In the nick of time too because i'm going to school in a week. :shock: I'm hoping I can finish everything. I swapped gas tanks last night. Fuel lines are such a bitch! The next 24 hours will be hectic, I'll try as best I can to keep updating.

[em99sport]

huh. I will try and find one for cheep. Theres a EGT sensor in there right? Any CEL issues with aftermarket uppipes?

Below is the link to Unabomber's uppipe FAQ on Nasioc. There is a section in that FAQ specifically addressing the resistor required to defeat the EGT CEL. I used an Accessport, so I didn't have to worry about the CEL, but this should work fine for you.

http://forums.nasioc.com/forums/showthread.php?t=443943

BTW: You could simply gut your stock UP, as that would be a free fix that wouldn't take too long. However, I personally think the aftermarket pieces are worth it, especially those that are coated.

Good luck getting her up and running.

[dppaladino]

Swap 90% done. I couldnt fit my mishimoto WRX radiator, so I need to find a replacement. Nothing in the engine bay is hooked up, but the entire drivetrain and suspension is all torqued down to spec. Unfortunately I won't be able to complete the swap until December when I come back from MSU for christmas break. I'll try to get some pictures up shortly.

[dppaladino]

Talked to ECS today, and after nearly 3 months, they finally finished up my merge. Not that it really matters since I wont be able to finish the car until December. I'm going to try and get pictures of the nearly finished product to share with DI.

[MConte05]

Also tighten down the fuel lines under the intake manifold on the WRX engine. 02's are known to have winter fuel leaks, pretty easy fix, just have to tighten the clamps.

[dppaladino]

good to know, especially for MT winters. thanks!

[daleyswanson]

looks good man, i'll be following this

[dppaladino]

Finally got some recent (end of august) pictures of how the car currently sits!
Enjoy:
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0674.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0684.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0685.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0687.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0691.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0696.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0699.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0700.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0705.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0707.jpg

[dppaladino]

http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0710.jpg
http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0711.jpg
:headbang:
Car hasnt looked this complete in a looong time. Only things left to be done are radiator install (mishimoto was far too beefy for my little GC), wiring harness, and lots of things to hook up in the engine bay. I won't be able to work on my car until December 19th, winter break, so for now my poor subaru sits in the garage of my neighbor's rental house across the street.

[MConte05]

http://i111.photobucket.com/albums/n128/dtpaladino/WRX%20Swap/IMG_0687.jpg

You look EXACTLY like me in this picture. It scared me at first. I was wondering why there was a picture of me leaking over a radiator here.

:shock:

[dppaladino]

You look EXACTLY like me in this picture. It scared me at first. I was wondering why there was a picture of me leaking over a radiator here.

:shock:
haha WEIRD! maybe you're the forgotten triplet...

[AWD>FWD]

I don't know if I have read everything but I have a few questions.. And yes, I realize you're on a budget here.

-Are you running the OEM downpipe on the car?
-Are you running the stock ECU tune?

Looks very good so far. Nice work. You should rape everything off that wagon and sell it on craigslist/eBay (tail lights, bumper, hatch, etc) to pay for parts. I understand wanting to keep it a 100% stock swap to keep it reliable for longer, those 2.0ls don't like to go more than like 90k before they spin a bearing so make the most of it.

[MConte05]

I don't know if I have read everything but I have a few questions.. And yes, I realize you're on a budget here.

-Are you running the OEM downpipe on the car?
-Are you running the stock ECU tune?

Looks very good so far. Nice work. You should rape everything off that wagon and sell it on craigslist/eBay (tail lights, bumper, hatch, etc) to pay for parts. I understand wanting to keep it a 100% stock swap to keep it reliable for longer, those 2.0ls don't like to go more than like 90k before they spin a bearing so make the most of it.

My 2.0L is well on it's way to 150,000 miles without any major issues. Have been running a stage two tune for about 20,000 miles. Will be putting an Evo III 16G on it sometime soon. We'll see how long it lasts after that. :mrgreen:

[dppaladino]

If maintained properly, these 2.0s will go for days. Not even close to the NA ej22 though. I had my mechanic pretty much overhaul the block once it was out of the wagon. And, if by OEM you mean the pipe from the donor car, then yeah its all stock. I had my wiring harness merged at ECS performance, and I won't be running any sort of aftermarket tune... untill I save enough for an AP.
I have a shed full of parts at home, wrx and RS alike, so keep your eyes out for a massive part out thread next summer. As for the wagon shell, I'm not entirely sure what to do with it yet. It would make a great rally chassis if you were planning on doing a Jackson Rally-style nose job on it.

[dppaladino]

My 2.0L is well on it's way to 150,000 miles without any major issues. Have been running a stage two tune for about 20,000 miles. Will be putting an Evo III 16G on it sometime soon. We'll see how long it lasts after that. :mrgreen:

That'll be sick! I'd love to run a small, insanely quick spooling turbo setup one day.

[dppaladino]

Drove the car today. Felt great. Few minor kinks to work out before I put the interior back in. Pictures soon!

[geekmonster]

i wanna see!

[Tim.Flat4]

Bummer to read that you had problems with ECS too. They've been slipping a bit but I hear they're getting their **** back together. However, good to read that you got it running recently!

I was curious, what model Hellas are those you have center mounted?

[dppaladino]

Bummer to read that you had problems with ECS too. They've been slipping a bit but I hear they're getting their **** back together. However, good to read that you got it running recently!

I was curious, what model Hellas are those you have center mounted?
Yeah... They aren't going to merge harness's anymore apparently. The lights are 4000 Rallyes with the Eurobeams (city light).

So I took my car to my mechanic today to have him look over everything and try and solve my fuel guage issue. While he was test driving the car, 2nd gear died and the transmission exploded. Drained the tranny and found all sorts of metal bits. :cry: It was fun for the week it lasted. Anyone in NV or CA selling a WRX tranny?

[Tim.Flat4]

Yeah... They aren't going to merge harness's anymore apparently. The lights are 4000 Rallyes with the Eurobeams (city light).

So I took my car to my mechanic today to have him look over everything and try and solve my fuel guage issue. While he was test driving the car, 2nd gear died and the transmission exploded. Drained the tranny and found all sorts of metal bits. :cry: It was fun for the week it lasted. Anyone in NV or CA selling a WRX tranny?

There is a guy selling a JDM tranny in Reno. Look in the classifieds at SECCS.org

Sorry to hear about you 'splosion. It happens though, a lot...

[dppaladino]

There is a guy selling a JDM tranny in Reno. Look in the classifieds at SECCS.org

Sorry to hear about you 'splosion. It happens though, a lot...
yeah it sucks...

that tranny is missing third gear.

[geekmonster]

that sucks, hopefully you'll be able to snatch up a new to you trans. i'll keep my eyes and ears open for you. are you looking just to replace the whole thing with another stock trans or would you be interested in getting a different gear set and do a rebuild?

[Tim.Flat4]

that tranny is missing third gear.

****, I forgot about that. Sorry about that. Still, it would be a good upgrade if you got it fixed and it would probably be cheaper too.

[dppaladino]

I'm just looking for another stock trans. I go back to MT on the 13th and I just want this car to be done!

[Tim.Flat4]

I don't know of any other leads in the NN/NC area. Hit the classifieds I guess...