Blue Porscheru Conversion, Subaru 2.5 SOHC NA with Suby Tranny Options

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Blue Porscheru Conversion

I started this project back in May of 2014 and wanted to share the journey with my friends and family.
There's something appealing to people about taking a left-for-dead vehicle and bringing it back to life.
I hope this build thread is a bit different than the others. It's a Subaru conversion which is not as common.

I am/was a newbie. This is my first car restoration, if you can call it that.
My welds are not pretty, but I've improved and learned throughout this process.
This is a great car for a first restoration. It's light, simple, and very cool- mid engine with a targa top.

This is the plan- We are starting with a 1971 tangerine 914 with light to moderate rust, nothing too serious.
The original engine was a 1.7. Like so many other 914's it ran but has been sitting for a long time.
The engine seems too far gone to try to rebuild it= lots of rust and corrosion.

Powerplant: 2003 Subaru Impreza TS 2.5 SOHC, Natuaral- No Turbo, Why? Plenty of Power for me and no turbo lag. See Engine Choices thread.
Transmission: Subaru 5MT 2003 Impreza TS
ECU from: 2003 Subaru Impreza TS
Electronics: Wiring Harness simplified by Small Car Performance
Axles: 944 axles and CV's with Subaru inside CV- 4 lug for now.
914 suspension.
No fender flares
Voltage Blue Metallic: (Honda color), Painted Sail Panels.

Before Pictures

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1486250894.1.jpg)

The Future Look- Concepts

The 914 visualizer, a very cool app.

Current Look:

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.imgur.com-17072-1607919164.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.imgur.com-17072-1607919164.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.imgur.com-17072-1607919165.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1459666779.1.jpg)



Contents

Axles
Blasting Glass Bead Videos
Battery Tray Area
Battery and Tray
Budget Scenarios
Brakes
Bumper - Valence
Clutch
Electronics
Engine Discussion
Engine Mount
Engine Work
Floor Pans and Engman Kit
Fuel Pump
Fuel Tank (Cleaning with Electrolysis)
Paint Prep and Metal Work
Paint Prep Continued
Radiator
Seats and Interior
Seats Re-upholstery Links
Transmission
Transmission Mount
Videos

This thread is for entertainment purposes only. I am not a certified mechanic.
There are many that have pioneered the suby conversion before me, but this
is my story.

Hope you enjoy this thread!

Chris

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1486249676.1.jpg)

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Subaru Engine Choices - Notes from various posters

From another's Post "What you need to decide is what level of power you want. A 6 cylinder makes the car VERY quick and fast compared to stock.
Lots of fun as long as you are ready for the car to become a completely different animal. If you want the feel of an enhanced version of a stock 914 go with a 2.5."

Subaru EJ Engine Wikipedia:Subaru Engine Wiki.

Engines:

HP Weight lbs/hp
EJ22 130-160 265 1.96
EJ25 165-200 298 1.81
Ej20tt 240 275
EZ30DR 216-245 315 1.85
EG33 225-275 0.00


EJ18: Found in Imprezas from 1993-1997. Rated at 110hp and 120 ft-lbs
EJ22 Phase I: Found in Legacies from 1990-1998 and Imprezas from 1995-1998.
Comes rated at 130hp and 137 ft-lbs, 135hp and 140 ft-lbs, or 137hp and 145 ft-lbs.
EJ22 Phase II: Found in Legacies in 1999 and Imprezas from 1999-2001. Rated at 142hp and 149 ft-lbs.
EJ22-T Phase I: Found in Sport Sedan and Touring Wagons (Legacies) from 1990-1994.
Turbocharged and non-intercooled. Rated at 160hp and 181 ft-lbs. Closed
Closed deck, cast pistons, forged rods, oil squirters: turbo motor. Poor flowing heads.
EJ25 DOHC Phase I: Found in Legacies from 1996-1999, Imprezas in 1998, and Foresters in 1998.in 1997-1999.
Rated at either 155hp and 140 ft-lbs in 1996 or 165hp and 162 ft-lbs in 1997-1999.
EJ25 SOHC Phase II: Found in Legacies from 2000+, Imprezas from 1999+, and Foresters from 1999+.
Rated at 165hp and 166 ft-lbs. There was a slight compression ratio change from 1999-2000 where it went from 9.7:1 to 10.0:1.
USDM EJ20: US Domestic Market WRX. Found in 2002+ WRXs. Rated at 227hp and 217 ft-lbs. Turbocharged, intercooled, open deck, and decent heads.
EJ25T DOHC: Available in 2004 in the Forester XT. Rated at 210hp and 235 ft-lbs. Turbocharged, intercooled, VVTi (Variable Valve Timing), and drive by wire.
EJ25T-STi DOHC: Available in 2004 in the WRX STi. Rated at 300hp and 300 ft-lbs.
Turbocharged, intercooled, AVCS (Active Valve Control System), drive by wire, intercooler sprayer, and semi-closed design.
EZ30R: Canbus Electronics require an aftermarket ECU for $2,000 (Not)
Found in the 2005–2009 Legacy 3.0R, Outback 3.0R and 2006–2008 Tribeca.

EZ30D: found in 2000-2003 outback and legacy’s. At roughly 212 chp from the factory, it seems to have the lowest hp number of the bunch.
You can tell the difference between the others by the aluminum intake and its single exhaust port heads (looks like a long slot or oval)
as compared the later 6’s or the metal timing cover/size when compared to the eg33. It has two plus sides when compared to the latter EZ’s,
cheap drive by cable, non CANBUS and you can pick this up for around $1-2k. Furthermore the 212hp mark is deceiving, both the intake
and exhaust is extremely constricting on the donor car and from the swaps that have been done/dyno’d (in the Subaru world) just
upgrading to something less restrictive will put power up to 230-240 CHP.

The EZ30D (according to Ian from Coldwater914.com) ranks motor highest in comparison to the other options in this category. Due to its more modern design and timing chain
(that does not need to be service for the life of the engine) it is smaller/lighter and more reliable than the eg33. On the other hand the ECU
on the EZ30D substantially less expensive than the EZ30R and EZ36R. However to clarify it does not have the VVT or AVCS of the later EZ’s.


More on the EJ22..

The EJ22 engine is part of Subaru's EJ series that was intended to replace the EA series of engines. This particular engine was first used in 1990 in
the Subaru Legacy. It also saw use in the Outback from 1995 to 1996 and in the Impreza from 1995 to 2001. There are two generations of EJ22
available through the large inventory on eBay. The EJ221 is the first model and featured 135 boiler horsepower at 5,800 rpm. The EJ222 is the
second, starting production in 1999, and it featured 142 boiler horsepower at 5,600 rpm. All EJ series engines are horizontal flat-four cylinders
with 16 valves and both single and dual overhead camshaft configurations were produced. These engines feature two rows of two horizontally
opposed cylinders that help to balance one another while the engine is running. This makes for a smoother ride and a lighter engine as additional
balancing components are not required to keep the engine from knocking around while in operation. The EJ22 engine is efficient, reliable, and
contributes to the long life of many Subaru vehicles.

There are actually a couple different varients of EJ22's in terms of actual parts. Ive counted 4, each with different HP numbers.

Anyway, the single port heads are actually in the more recent models... 99-01 I believe. And there was discussion before about how the MY96 EJ22
had lighter weight rocker arms that might add horsepower to other model EJ22's, but thats kind of off topic...

Here are the HP/Torque numbers for various years:

99-01: Horsepower: 142 hp Max Horsepower: 5600 rpm Torque: 149 ft-lbs. Max Torque: 3600 rpm
97-98: Horsepower: 137 hp Max Horsepower: 5400 rpm Torque: 145 ft-lbs. Max Torque: 4000 rpm
95-96: Horsepower: 135 hp Max Horsepower: 5400 rpm Torque: 140 ft-lbs. Max Torque: 4400 rpm
93-94: Horsepower: 130 hp Max Horsepower: 5400 rpm Torque: 137 ft-lbs. Max Torque: 4400 rpm

The bore and stroke are same on the 93-96 2.2's, 3.82x2.95 but the compression ratio is 9.7:1 for the 95-96 as opposed to 9.5:1 for the 93-94. T
he camshaft elevation is different between the two as well as the valve spring height. The main bearing journal diameter is different along
with the connecting rod journal diameter (slightly, .0001 difference). The piston ring gap bottom compression is different between the two.
I cant tell if any part numbers are different though, im just looking at specification numbers from my chiltons guide. Sucks there isnt a newer
guide for the other models though... Cant help past MY96

Links:

Subaru 2.X Build Thread on NASIOC

Franken Motor or Mix and Match various parts Engine Build Discussion NASIOC

Franken Motor- (2.2L heads on 2.5L Block)

franken motor shopping list 2.5 block with 2.2 heads

NA Horsepower

Subaru engine swap

How to pull a WRX engine

Engine Tear Down

I want to build a 2.x engine

"Built Motor Discussion" Links to Great Threads

Pull your own motor. Lots-o-pics