1995 Legacy Turbo. EJ22-T Build

[mattnes17]

Hey fellow legacy owners!

I started this build thread on my local Subaru forum (http://mnsubaru.com/) and I figured I should post it on here where its Leggy goodness will be be truly appreciated ;)

I bought the legacy this past fall in Denver CO and drove it back to MN on a failing engine and mostly on 3 cylinders. Fun stuff! Its a 1995 Subaru Legacy L with 160K miles. Essentially rust free. The engine I swapped in was from a 1996 Impreza, EJ22E with 170K miles I picked up for 500 bucks. My plans are to do a pretty generic EJ22 turbo setup.

I'm going to dump-post all the stuff i've done so far and then post updates from here on out. Any tips or advice is appreciated!

[mattnes17]

The car the engine came from
https://sl-i.net/FORUM/images/imported/2015/01/ac26def58a7343d78fd930701847a1ba-1.jpg

Heads going on
https://sl-i.net/FORUM/images/imported/2015/01/photo7-1.jpg

https://sl-i.net/FORUM/images/imported/2015/01/image2jpeg-1.jpg

New gates timing belt with WRX water pump
https://sl-i.net/FORUM/images/imported/2015/01/F2614E0CE16C440286ADF077D2F73AE4-1.jpg

Oil separator
https://sl-i.net/FORUM/images/imported/2015/01/A9143E6EE5424AA581AF8988E75E4B62-1.jpg

Resurfaced flywheel
https://sl-i.net/FORUM/images/imported/2015/01/C58C9EB9EBBD4F66B3773FD8DB4DC1AF-1.jpg

It took me only 2 hours to pull the engine this time! I felt like a bad ass.
https://sl-i.net/FORUM/images/imported/2015/01/0bb8506a39124d4bbea0af0b5fb4bb9b-1.jpg
The bay is nice and dirty. I will grab some degreaser and maybe even the powersprayer if its warm enough and clean things up a bit.
https://sl-i.net/FORUM/images/imported/2015/01/0ab0f7a559774e1280e2be138a6df41e-1.jpg
I'm going to swap intake manifolds because there are some subtle but definite differences between the Impreza one and the Legacy one. I'll also be throwing my grimmspeed phenolic spacers on too

Got a new oil line installed with the proper banjo bolts
https://sl-i.net/FORUM/images/imported/2015/01/d53ccd8110f642fc80444e8046f93db8-1.jpg

My new center timing cover also came in the mail. While installing it cracked slightly :mad: I just put a little dab of RTV on it to keep it sealed. Also got the crank pulley and the belt back on.
https://sl-i.net/FORUM/images/imported/2015/01/4ED6E67BC2854E66814A8DA0499CFF06-1.jpg

I will be swapping the intake manifolds tomorrow afternoon. little by little, getting closer!

I got the oil cooler gasket while I was away. Last night I torqued down the cooler and picked up some Rotella T5 and a cheap Microguard filter.
https://sl-i.net/FORUM/images/imported/2015/01/c4ec9dba8b78491c85bd859cb77042bb-1.jpg
I will change the oil at 1K miles as a sorta "break in" period.

I installed my Group N mount yesterday
https://sl-i.net/FORUM/images/imported/2015/01/f309df869d0a4d94b2e612a1d46e83fb-1.jpg
Also installed some new Kartboy shifter bushings and filled up the trans with some fresh gear oil. The trans mount in conjunction with the bushings has completely changed the shifter feel. The gears are easier to find/shift into and there is a lot less play in the shifter. I also cleaned up the trans a bit. Nothing too crazy, just cleaned out all the old chunks of clutch/dirt/oil.
https://sl-i.net/FORUM/images/imported/2015/01/6afff2af556d4c2bacab5293d533cd07-1.jpg

I got the manifold off
https://sl-i.net/FORUM/images/imported/2015/01/90D1E0211E0448E48C2174B3A3498A9E-1.jpg

Pink tops and Phenolic spacers installed
https://sl-i.net/FORUM/images/imported/2015/01/30A0152D6379464BBFC6CA3B9D758DD8-1.jpg
https://sl-i.net/FORUM/images/imported/2015/01/377F8041ED6F4241BD58ECDB309CDEC5-1.jpg

New Exedy clutch on
https://sl-i.net/FORUM/images/imported/2015/01/1BE80BB3D52B4D888450B57D74FD0B53-1.jpg

Engine dopped in
https://sl-i.net/FORUM/images/imported/2015/01/F3110F6DFE2B4981A4645497BCF8C10E-1.jpg

Subframe slice (to be welded as soon as she runs)
https://sl-i.net/FORUM/images/imported/2015/01/3D4AABEEFC6E4410A33ED9C7CC82FE6E-1.jpg
https://sl-i.net/FORUM/images/imported/2015/01/9C436336A7DF4825BA940D6DB7B29F44-1.jpg

Literally snapped this picture as my phone turned off, kinda dark. But I mocked up the FXT intercooler as well.
https://sl-i.net/FORUM/images/imported/2015/01/44fe2db9d85942bb992c87706fb50e12-1.jpg

[mattnes17]

Thats about where I'm at right now. Slowly getting everything plugged in, plumbed, and bolted down.

[dynonacht]

Hey matt, I'm also on mn subaru! Welcome to sli, if your ever lookinh for a hand working on the car drop me a line! Hope to see this around.

[mattnes17]

Hey matt, I'm also on mn subaru! Welcome to sli, if your ever lookinh for a hand working on the car drop me a line! Hope to see this around.

Cool cool! I will definitely let you know if I need any help. Good to know there are a few MN guys on here. I believe Phil (phi11) is also a user on sl-i. He is the one that suggested I post my build on here.

[mattnes17]

Quick update.

Its super cold in MN this week (10'F at the moment), much to cold to mess around in the garage. It should be in the 30's on Friday. If that's the case I will take Friday off of work and spend most the day wrenching.

[dynonacht]

Yeah he's on here. What area are you in? I'm in eagan.

[meepers]

wish I would have caught your post a little sooner. You should seriously consider replacing the throw out bearing fork with a new unit. I went through all the hassle putting a fresh 2.2 in my 97 Outback to put a whopping 3000k miles on it before the fork broke. I wasnt aware they were a weak spot as my other car has a WRX tranny I never thought to check it. It is a cheap enough part to replace to not be stuck with a car that wont let the clutch disengage.

[mattnes17]

wish I would have caught your post a little sooner. You should seriously consider replacing the throw out bearing fork with a new unit. I went through all the hassle putting a fresh 2.2 in my 97 Outback to put a whopping 3000k miles on it before the fork broke. I wasnt aware they were a weak spot as my other car has a WRX tranny I never thought to check it. It is a cheap enough part to replace to not be stuck with a car that wont let the clutch disengage.

Interesting. Ive never heard of the fork being a weak spot either. Did you put in an OEM replacement clutch?

[meepers]

It was the clutch that was in the car when I bought it. I only pulled the 2.2 out of a runner and dropped it in. I was not aware that the forks were a weak spot either. that is why I did not replace it when it was apart. Took me all of 15 seconds to figure out what the problem was when the clutch pedal started feeling odd. Lots of info on the interwebs...

http://www.realabstract.com/cars/subaru5.jpg

[mattnes17]

It was the clutch that was in the car when I bought it. I only pulled the 2.2 out of a runner and dropped it in. I was not aware that the forks were a weak spot either. that is why I did not replace it when it was apart. Took me all of 15 seconds to figure out what the problem was when the clutch pedal started feeling odd. Lots of info on the interwebs...

https://sl-i.net/FORUM/

Cripes!

Now I'm kinda worried... But I'm not going to pull everything back out at this point just for the fork. If it breaks it breaks I guess and I'll have to deal with it then..

[BDAlex95]

Welcome to the forum! It's interesting seeing someone turbo the EJ22E without doing a hybrid engine, I'd like to see where this goes. Lookin good so far.

[meepers]

I hear ya Matt. Dont stress about it, but if you feel the pedal get mushy.... seeing that your clutch is cable, I can pretty much tell you stop driving it. Basically once it breaks, you have NO clutch. Oh, and order new TO bearing clips from suby too. Cuz they will be gone when the arm lets go.

Did your Impreza have dual port heads? what if any clearance issues did you run into on the up pipe? My dad has a 91 Legacy 2.2 dual port head car that we are going to do a td04 on waste gate pressure. Just going to bump up the fuel with a rrfpr and 2.5" exhaust. I really wish I could find a wrecked or non running SS model here for less then 3k and just do the damn swap for him.

[mattnes17]

Welcome to the forum! It's interesting seeing someone turbo the EJ22E without doing a hybrid engine, I'd like to see where this goes. Lookin good so far.

I heavily considered the typical "hybrid" (ej22 block w/ ej25 sohc heads) but I got these EJ22T heads for next to nothing so I decided to run with it. My comp ratio is right around 9.5 to 1 or a bit lower because of slightly thicker HG's. That comp ratio and 5 to 7 pounds of boost should do fairly well.

[dynonacht]

Hybrid is usually dohc ej25d heads fyi. Does that subframe cut look like something you vould do with the engine in vehicle?

[mattnes17]

I hear ya Matt. Dont stress about it, but if you feel the pedal get mushy.... seeing that your clutch is cable, I can pretty much tell you stop driving it. Basically once it breaks, you have NO clutch. Oh, and order new TO bearing clips from suby too. Cuz they will be gone when the arm lets go.

Did your Impreza have dual port heads? what if any clearance issues did you run into on the up pipe? My dad has a 91 Legacy 2.2 dual port head car that we are going to do a td04 on waste gate pressure. Just going to bump up the fuel with a rrfpr and 2.5" exhaust. I really wish I could find a wrecked or non running SS model here for less then 3k and just do the damn swap for him.

Alright. I will definitely keep that in mind.

The engine was originally a single port but the car its going unto is a dual port.
I had to cut the subframe for the uppipe. Its a pretty big notch, but I will be bracing it. Besides that, everything else has gone very smoothly. No other filament issues to speak of.

[mattnes17]

Hybrid is usually dohc ej25d heads fyi. Does that subframe cut look like something you vould do with the engine in vehicle?

I thought the EJ25D was SOHC. My bad :P

You could definitely do it with the engine in the car but it would probably be a pain in the ass. I used an angle grinder which is kinda big and bulky, but if you pulled all the NA exhaust stuff off and used a plasma cutter from below or got wild with a Dremel you could get a good notch in there.

[rkrenicki]

The D in EJ25D is for DOHC.. The rest of the EJ25 line is SOHC.

[mattnes17]

The D in EJ25D is for DOHC.. The rest of the EJ25 line is SOHC.
That makes perfect sense! Should picked up on that :P

[mattnes17]

Its almost above freezing here in MN! I think i'm going to take off from work shortly and spend some quality time with my legacy.

[mattnes17]

Spent Friday and Saturday routing/installing coolant lines, PCV, crank vents, wiring, etc. Also worked out how i'm going to tackle the intake system and I should have all the parts ASAP because I ordered the last few on amazon, with prime shipping of course. They should be here early next week.

I sold the Legacy GT Limited I had been driving around last week. Biking to work is COLD. I'm trying to get this thing up and running soon.

[meepers]

Bbrrrrr lol

[mattnes17]

Parts are taking FOREVER to get here. I am so impatient. I check the tracking like 5 times a day. haha.

I ordered a silicone Y pipe for my forester intercooler, a silicone coupler for TB to TMIC, a silicone 90 for the TDO4 inlet, and a silicone 45 for fabbing up the intake system.

Today at work I'm going to spend my lunch hour in the machine shop building a BPV adapter plate.

[r3v_v3ng3]

That's what sucks sometimes waiting for parts to come in. I order parts from CA and it still takes 3 to 4 days and its the same state :smt076


Its gonna be a beast when its done :)

[mattnes17]

That's what sucks sometimes waiting for parts to come in. I order parts from CA and it still takes 3 to 4 days and its the same state :smt076


Its gonna be a beast when its done :)

Haha, I know the feels man.. I kinda wish I would bought everything local at maperformance here in MN. But whatever..

I'm so excited to drive it!!! lol

[lord flashheart]

I dig your build man! This is similar to my old setup and i loved it. I would recommended putting 25D heads on it down the road. I have run nearly every set up imaginable and my old 22/25D turbo hybrid was the best. The most fun you could have in a car.