Tim's EA82 to EJ20G conversion - MY wagon

tim_81coupe · Post by **tim_81coupe** » Sat Jul 29, 2006 5:07 pm

Hey everyone.
I'm starting this thread to do what I've sort of been trying to do for the last 4 years. I want to get a good amount of EJ conversion information up on the net, and I've decided my current project is as good as any to get it started.
Over the next few weeks I'm going to build (with many a helping hand) my WA-QLD BYB BBQ trek-mobile. The vehicle I am going to use is my current MY wagon.

Many of you are familiar with my cruddy beige wagon, it is the one in my signature. Its a 1982 DL with no factory frills. In the 5 1/2 years I've owned it its seen many different configurations and its been a car thats taught me a lot.

At the moment it's fitted with a Weber'd EA82, 5 speed dual range box, 3" lift kit (made by Vidler) 27" Kelly crap-spec tyres, welded rear diff, rear air shockies, Kings springs etc etc. It's a fun car, not really suited to the daily driving duties I've put it through, but nonetheless fun. As you can probably guess its also slow as a wet week, even a Charade in stock trim can burn it off at a set of lights.

But all thats about to change. I'm fitting the EJ20G from my little Leone coupe along with its 5 speed AWD box and VLSD. It will be receiving the full complement of performance bolt ons that my coupe had. It's also going to be fitted with the coupe's stereo and some interior parts, as well as a 4" lift kit and hopefully a set of 27" Toyo tyres (wink wink Mike :P)/

The final spec list should look something like this:

1982 Subaru 1800 wagon

EJ20G turbo from a 93 Legacy GT
TD05H from an early WRX STi
STI TMIC
550cc injectors
Underdrive pulleys
Revised intake with pod
3" turbo back exhaust (a little quieter this time!)
4" BYB lift kit
5 speed single range AWD gearbox
4.11 rear viscous LSD
27" Toyo's
DBA Race series front rotors
DBA Slotted series rear rotors (yes, RX discs)

and lots of in-car electronic bits.

First order of duty is to dismantle the coupe. This will basically lose all of its engine and drivetrain before work begins on the wagon.

To get the thread started, here's two pictures of me starting the dismantling of the coupe, I've stuck them on imageshack because of the filesize limit on attachments.

http://img89.imageshack.us/img89/8961/dsc00700nn5.jpg
http://img136.imageshack.us/img136/5035/dsc00705nr4.jpg

tim_81coupe · Post by **tim_81coupe** » Sun Jul 30, 2006 11:55 pm

This weekend I've removed the EJ20G from the coupe, along with the wiring, fuel system, radiator and gearbox. I'm not kidding when I say this only took me about 3 hours. I'll be putting more time into this later, honestly

.

This week I'll be stripping the EJ down a bit, replacing various water hoses etc. I'll be fitting the new clutch, new plugs and maybe a new water pump next Saturday in preperation for engine fitment next Sunday. That means I have plenty to do this week after work. The EA82 is coming out of the wagon along with its gearbox and the engine crossmembers will need to be swapped between the two cars. I'll have to get some new bolts for the 4" lift kit too.

I do have some pictures of my progress but they don't really show anything of an actual converted MY, they basically show an engine sitting next to one!

Stay tuned.

TW83 · Post by **TW83** » Mon Jul 31, 2006 1:42 am

Just wondering what the reason is for the swap?. I feel sorry for the coupe.

85wrx · Post by **85wrx** » Mon Jul 31, 2006 8:26 am

Since you have fitted this engine and gearbox combo to a coupe( similar to what I am doing minus the turbo). Was there a need to massage or modify the tunnel to fit the gearbox? Was the coupe an auto or manual originally? How did you design the gearbox X member? What did you do to the chassis rails to fit this motor? If you could send pics that would be great.

Darryl

BlackMale · Post by **BlackMale** » Mon Jul 31, 2006 10:19 am

Sounds like fun Tim. Let me know if/when you need a hand i am in the que.

tim_81coupe · Post by **tim_81coupe** » Mon Jul 31, 2006 7:19 pm

TW83: The coupe got a defect notice and there was no way it was going to pass rego in the state its in. Plus there is some pretty bad rust spots under it, the more I pull it apart the better I feel about it.

85WRX: You're say you're doing an EJ conversion minus the turbo, is your motor SOHC? If it is, then no subframe mods need to be done. I'll post pics tonight if you are fitting a DOHC motor. The coupe was originally a manual and no tunnel mods were performed. The engine crossmember was lowered 25mm to clear the bonnet over the motor and this in turn would have lowered the box slightly. It was very close and in the end when the mount started sagging it did touch the tunnel slightly. The gearbox crossmember is still in the car at the moment, I'll take a photo of it when it's out. It isn't a good design though, I've never been happy with it.

Jaffa: you're more than welcome to come around any time and have a look, I should be right for the most part on my own. Thanks for the offer.

tim_81coupe · Post by **tim_81coupe** » Sun Aug 06, 2006 2:16 am

Got a lot done today, huge thank you to AndrewT for lending half a day to my wagon! Cheers buddy!

We got the engine and gearbox out of the wagon and the crossmembers out of both cars. We cleaned them up and sat them side by side for a little photo shoot (will post later).

One thing we did notice though, my BYB 4" lift kit seems to be 3.5"! Not sure if I'll install the whole kit now, I'm thinking of installing the engine crossmember lift but not the strut tops. This will give me good negative camber but lower ground clearance.

Off to bed now, fitting the turbo crossmember into my wagon tomorrow and hopefully the EJ20G too. I'll at least be dummy fitting it to see how it goes - stupid me forgot to get spark plugs this week! Hoping I can fit them with the motor installed, will be interesting to see though.

SuBaRiNo · Post by **SuBaRiNo** » Sun Aug 06, 2006 11:10 am

Good work Tim... keep it up mate..

Dave

tim_81coupe · Post by **tim_81coupe** » Wed Aug 09, 2006 1:26 am

Things are progressing slowly, but they are progressing. Engine and gearbox are now in the wagon with the clutch lined up. I've hit quite a few stumbling blocks: rounded the head off a gearbox crossmember nut, tore the captive nut for the steering rack out of the crossmember and covered my garage floor in gearbox oil to name a few.

Tomorrow I'll do some small stuff like put the starter motor in and attempt to sort out the gearshift linkages. Throughout the week and this weekend I'll hopefully install the radiator, wiring and rear diff.

Oh and the front hubs and discs are off at the moment as I'm fitting the coupe's drilled and slotted rotors. Hopefully I'll finish that off tomorrow too.

mattims · Post by **mattims** » Wed Aug 09, 2006 4:59 pm

let us know if you want me to come around and help. Im not particularly cluey but i can lift heavy things ..

MUDRAT · Post by **MUDRAT** » Wed Aug 09, 2006 6:07 pm

We are all watching . . . nothing for me to add, if anyone knows what they're doing it'd be you.

SuBaRiNo · Post by **SuBaRiNo** » Wed Aug 09, 2006 8:16 pm

Not to mention Matt can run fast... so if u want something that u can't actually afford to pay for then send him.

Thats not an invite to take stuff from Hatchie btw.

Dave

tim_81coupe · Post by **tim_81coupe** » Mon Aug 14, 2006 11:49 pm

Not a lot has progressed in the last week, quite a pity but nonetheless I won't be pushing back the expected time to have it on the road. It should go for its first drive by the end of this month.

6 days since the last update and all I have done is fitted the coupe's front brakes and played with the gearbox crossmember a bit. The linkages have worked out badly - they don't line up at all with the lift. See my post in the wanted section - I'm after a new set at the moment!

Have fitted so far:

Coupe's modified crossmembers
EJ20G
New clutch
5speed box
Coupe's front rotors

Still to go:

New surge tank and fuel system
Radiator & Hoses
Wiring Loom and battery(s)
Hydraulic Clutch setup
Rear Diff and Tailshaft
Rear RX discs
Intercooler and intake piping
Interior mods
Gearbox linkages

So from now its the fiddly stuff, could be a breeze but more likely will be a nightmare. I'll keep you all posted.

SuBaRiNo · Post by **SuBaRiNo** » Mon Aug 14, 2006 11:51 pm

Keep up the good work.

Dave

KERAZY · Post by **KERAZY** » Tue Aug 15, 2006 2:43 pm

reckon it sounds a bit complicated. hope it all runs nicely (the conversion and the finished project). have you taken any photos of the conversion?

tim_81coupe · Post by **tim_81coupe** » Wed Aug 16, 2006 9:07 pm

I've taken some photos here and there, although the priority has been getting it going in the short timespan I have. I work full time and have a lot of out of work obligations at the moment, so every minute counts really.

Its really not too complicated when you've done it before. You begin to see each bit as a seperate thing, and all together it doesn't seem like a huge amount. It's still a little trickier than the average engine swap though.

Today I fitted the radiator and started on the hydraulic clutch swapover. I might have a bit of a go at the wiring and interior tonight, although not having good lighting where I'm working is starting to hold things up.

One thing I did notice tonight is how the lift kit heavily affects the intercooler situation. I might have to look into a WAIC or front mount, whatever it is the stock stuff won't bolt on. Plus I'm now thinking an air/air setup is probably not a good idea due to the mud this car will most likely see.

wagonist · Post by **wagonist** » Wed Aug 16, 2006 9:37 pm

hmmm.... interestink
what did you do for rad fans in the coupe (or did you fit them in front of the rad)?

SuBaRiNo · Post by **SuBaRiNo** » Wed Aug 16, 2006 10:07 pm

You should buy some of them $30 flood lights from bunnings... they don;t only put out some killer light but they will keep you warm too.

Dave

tim_81coupe · Post by **tim_81coupe** » Sat Aug 19, 2006 5:53 pm

In the coupe I had one 10" thermo mounted in front of the radiator.... due to the big core the car kept its cool. Did warm up on hot days though.

I've hit a big setback in the conversion process, and it happened while fitting a bullbar to a 78 series personnel carrier yesterday. I've hurt my shoulder, not sure how but its limiting my movement a fair bit. I figured I'd stay inside this weekend and do my wiring, however I seem to have left all my soldering gear at work! The prospects of me doing much work this weekend are made even worse by the bloody weather!

The "still to go" list I wrote on Monday is mostly accurate, I have mounted the radiator now and have a good idea of what hoses I need, but the rest is still the same. Plus I forgot about the exhaust on that list too - it needs some hefty mods!

The intercooler situation is not looking good - I don't think I can easily fit the Subaru topmount WAIC and I've started looking outside the square. If push comes to shove I'll get it running on 5psi with no cooler, performance comes second to having it running!

I should hopefully get over this shoulder thing soon, until then I'm going to try the fiddly stuff. This monday I'll visit the auto parts store and spend some money, I need a new clutch master amongst other things! I'm also going to pospone the rear brake swap until the car is driving - its not that hard and I do have better things to do at the moment!

I'll keep you all posted!

tim_81coupe · Post by **tim_81coupe** » Wed Sep 06, 2006 1:49 am

Well the shoulder pain lasted a while, but it has left something a bit worse. Slackness. I've not been bothered working on the car lately, this is my own fault. Working long hours at work then coming home to more of the same is a bit draining, as I'm sure most people on these forums would know first hand.

The thought of the finished product sort of has me thinking "whoop-dee-doo", as in I'm feeling not overly impressed with what the final product will be. Sure, not many lifted MY wagons have EJ20G powerplants but hey, I'm hardly breaking new ground here.

So, in addition to the above list, which is still mostly accurate, I have to add another thing. My bottom hose is a no-goer, so it looks like the radiator is going to need to be modified again to take a bottom hose. The wiring is partly done, I still need to go through my box containing all the old loom plugs and find the gearbox one (I want reverse lights). Still gotta run the wiring into the car and there were some tatty wires in the MY harness I was going to replace.

I still need to work out a master cylinder, it is indeed a PBR P6575, albeit with a modified clevis fork and pin, really do wish I'd written more stuff down in my initial EJ conversion to the coupe.

The surge tank is about a month overdue but should be coming any day now. The injectors are still wrong and I haven't done anything about them yet.

Haven't even swapped the diff. Someone tell me I'm slack

.