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The CA BAR Approved EJ207 Version 6 Build
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Old 11-27-2016, 01:08 AM   #21
Razor7
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Well, I'm mostly done.

- Engine is in
- Wiring is in



But naturally I ran into a few snags which have slowed me down. I chose to install a 2013 WRX brake booster and master cylinder, to replace the 222k mi stock mushy booster and master. Everything lines up, but the new master cylinder uses a M12-1.0 (1/4" ID) brake line fitting - ours are M10-1.0 (3/16" ID) brake line fittings. There are converters out there, but few are easy to come by with an inverted flare fitting. I've got an idea in the works.

The new A/C condenser's inlet and outlet hit the JDM radiator, and aren't much better with the ebay special 2-row I've been running. I'll likely need to buy a stock radiator, or do some research as to how aftermarket ones work with the condenser.

The JDM STI V5 A/C pump uses different hard line fittings than the RS, and has a different pinout and plug. This wouldn't be an issue, but my harness came back with an RS plug, so I might as well keep it clean. Gotta order a RS pump.

The expansion valve I ordered from Rock Auto won't work. It doesn't have the indents for the screw heads to sit inside of, nor is it thick enough (off by ~8mm).

Looks like there's also a change to the midpipe heat shield on the WRX.

Finally, getting the bellhousings together was one of the most convoluted, stupid processes that I've endured. Since I left the downpipe on, I had to remove the passenger front axle to get enough room the come down. The head shield for the turbo and first cat caught and got stuck on the transmission axle stub and bellhousing causing the input shaft to go wonky and get off centered. It took me 6 hours to get the engine and trans mated and 100%...

From here I'll be knocking out these issues ASAP in an effort to get up and driving in <2 weeks. Really the main issue will be shipping.

-TC

Last edited by Razor7; 11-27-2016 at 01:11 AM..
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Old 11-27-2016, 08:41 AM   #22
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I'm pretty sure I got an RS AC compressor on the shelf I won't be using.
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Old 11-27-2016, 10:04 AM   #23
Razor7
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Quote:
Originally Posted by FryphaX View Post
I'm pretty sure I got an RS AC compressor on the shelf I won't be using.
Since my goal is absolute perfect A/C (I've never had working A/C in this car over my 6 years of ownership), I've gone ahead and ordered a new compressor.

Thanks though - we will see how a reman unit holds up.

-TC
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Old 11-28-2016, 06:14 AM   #24
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California is a pain in the ass. I'm glad I don't have to worry about anything but registering my car. I salute your effort
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Old 12-04-2016, 11:45 PM   #25
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Niceeee. Doing some serious work. Surprised to see a fellow spartan, but I guess I've seen a few RS in the garage. Haha
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Old 12-05-2016, 12:52 AM   #26
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She starts!

Still have CELs to sort out, brakes to fix, fluids to bleed, and general tidying up.

-TC
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Old 12-19-2016, 09:47 AM   #27
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Since my last post I've:
- Resolved 5 CELs
- Resolved an issue with the new A/C Compressor (had to grind down a portion of the injector/fuel rail cover)
- Re-installed an axle, which proved more difficult then it should have been
- Resolved a couple oil leaks (turbo)
- Replaced a couple of crushable gaskets (turbo)
- Replaced a missing heat shield mount
- Installed new turbo upper and lower heat shields
- Installed radiator fans and verified wiring
- Re-assembled interior
- Verified proper wiring for audio
- Bled brakes
- Bled clutch
- Resolved brake issue (larger master cylinder on car with smaller hard lines. Write up is here)
- Re-assembled engine bay for the most part



Once again the motor runs, but it's in limp mode due to a P1507 error. Since the IACV was pretty gnarly, I've ordered another.

So there's some final buttoning up, an oil change (I'm doing multiple flushes to remove any debris), and generally topping it off and adjusting things, but I should be <5 hours from being able to drive her.


Total to date:

- The motor has now cost me $8300. This included the full build, all new rubber, and basically making it as close to a 0 mile motor as possible (with the exception of redoing rings and honing the cylinders. Everything else has been done)

- The motor also took me between 90-100 hours to take apart and rebuild

- The motor installation into the RS has taken (to date) 94 hours. It'll likely round off at 100 (edit: it does) when all is said and done

I'll keep you all posted.

-TC

Last edited by Razor7; 10-23-2017 at 11:17 PM..
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Old 12-28-2016, 12:38 AM   #28
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We're done!

Well, all the big stuff is handled and I have driven about 3 miles. Still some small things to wrap up, but the eternity on jack stands is over.



-TC

Last edited by Razor7; 01-16-2017 at 12:11 AM..
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Old 12-28-2016, 08:34 AM   #29
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Awesome build man. It will be an extremely fun car.
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Old 12-28-2016, 01:27 PM   #30
Razor7
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Quote:
Originally Posted by hail2theTheif View Post
Awesome build man. It will be an extremely fun car.
Thanks man! It's a blast already, but with 1000cc injectors and the VF28 back on there (after the BAR process), it only stands to be more fun.

-TC
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