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Mailman’s 2000 RS Coupe: EJ257 / JDM EJ205 Hybrid Swapped

34K views 184 replies 32 participants last post by  bue car 
#1 · (Edited)


As of 12/18/2022: 190251 chassis miles
Swapped at 188706 miles
1545 miles on swap

This is my 2000 Impreza RS coupe which has been my daily driver since 2004. I bought it used from a gentleman in Dallas who had it set up for autocross. Faced with the prospect of buying a new car, I couldn’t find it in myself to part with it! Now after years of wear and tear I am committed to making this thing new again, and to eventually make it into the STI it always wanted to be :)

--- GOALS ---

Overall:

  • RSTI with daily driven power
  • OEM+ style build
  • "Luxury RS" finish
Short/mid-term Goals:
  • USDM EJ257 / JDM EJ205 Hybrid Swap (currently in post-swap tuning phase)
Long-term Goals:
  • Rear suspension refresh
  • 6-speed swap
  • V6 body trim
  • Upgrade stereo
  • Interior refresh

--- BUILD NOTES ---

Engine & Exhaust:

  • USDM EJ257 / JDM EJ205 Hybrid Built Motor
    • 2018 STI RA OEM Shortblock
    • JDM EJ205 Heads, Manifold, Headers
    • IHI VF48 "Hi Flow" Billet Turbocharger
    • 2021 STI Intercooler
    • Tomei Silcone Inlet
    • SPT 02-07 WRX Intake
    • Grimmspeed Lightweight Crank Pulley
    • STI "Dark Blue" 565cc Injectors
    • STI Group N Engine Mounts
    • 2011+ WRX/STI 100a Alternator
    • 07 STI Power Steering Pump
  • HKS Catless Up-pipe
  • Cobb Tuning Turbo-back Exhaust w/ GESI Hi-flow Cat
Transmission:
  • JDM 02 WRX 5-speed Transmission TY754VBBAA 4.444 FD
  • STI Group N 5-speed Transmission Mount
  • STI Group N Pitch Stop
  • XClutch Stage 1X 02-05 WRX Clutch
  • XClutch Chromoly Flywheel 13.42lbs
  • 02-05 Clutch Master Cylinder
  • Kartboy Transmission Crossmember Bushings
  • COBB Tuning Short Throw Shifter
  • Energy Suspension Shifter Bushings
Steering and Suspension:
  • 04 STI Power Steering Rack
  • KYB AGX Struts
  • King OE Height Springs
  • STI Group N Strut Mounts
  • JDM Aluminum Front Control Arms
  • STI Group N Front Control Arm Rear Bushings
  • Cusco Rear Sway Bar
  • SPT Front Strut Tower Brace
Wheels/Tires/Brakes:
  • 06-07 WRX 4/2 Piston Brakes
  • Powerstop Stainless Brake Lines
  • Sparco Assetto Gara Wheels, 17x7.5 Matte Graphite Silver
  • Bridgestone Potenza Tires, RE980AS 215/50R-17
Exterior:
  • Full Repaint
  • JDM Tail Lights
  • Depo Clear Corners and Side Markers
  • Painted Shark Fin Antenna
  • 06-07 STI Badging
  • Full LED Lighting
Interior:
  • 2006 STI Floor Mats
  • 02 WRX Pedal Covers
  • IAG Floor Mat Bracket
  • STI Duracon 5-speed Shift Knob
  • GC Navigation/Gauge Pod
  • Alpine CDE-SXM145BT Single DIN Receiver
  • Infinity Reference 6000cs 6.5" Component Door Speakers
  • Infinity Reference 6522IX 6.5" Coaxial Rear Speakers
  • Pioneer 12" Subwoofer in Custom Box
  • Noico 80mil Sound Deadener, ~120 sqft
  • Full LED Dash Lighting

--- TABLE OF CONTENTS ---

1. Original Photos
2. Head Gasket Repair
3. Shifter Linkage/Bushings, Transmission Mount, Interior Trim
4. Suspension, Wheels, and Tires
5. Repaint!
7. Shark Fin Antenna
8. Sound Deadening
9. STI V8 Steering Wheel
10. JDM EJ205 Powertrain Received!
11. 06/07 WRX 4/2 Piston Brakes
12. JDM 5-Speed Install
13. Engine Rebuild as EJ257 Hybrid!
14. 04 STI Steering Rack, JDM Control Arms, Crossmember
15. After a break... the swap resumes
16. First start up and break-in
 
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1
#105 ·
More drama, the "04" crossmember I received turned out to be an 05-07 crossmember. Since I'm replacing the steering rack, that wouldn't be a big deal, but I already bought a 04 STI rack. I opted to contact the ebay seller of the crossmember and they are sending me an actual 04 crossmember as replacement. Once that gets here I'll clean that one up and throw it in. I also purchased some JDM GC8 STI control arms. Following a suggestion on this forum, I replaced the front bushings with GD versions to eliminate the need to shim the control arms. I test fit the new bushings with the crossmember and its an exact fit. I finished off the control arms with a good cleaning and new Group-N rear bushings.









 
#108 ·
I finished assembling the front subframe. Here's the final setup:

04 STI cross member
04 STI power steering rack
Whiteline 22mm front sway bar GD WRX Wagon
JDM GC8 STI front control arms
GD front control arm front bushings
STI Group N front control arm rear bushings
Cusco front end links GD WRX Sedan
New bolts, stock crossmember brace, ball joints, sway bar brackets, and jacking plate.

 
#113 ·
Sorry to disappoint a new follower... I've had an unexpected work commitment pop up recently that will keep me out of town for the next few months, so I'm going to have to put this project on hold until next spring. Sucks... especially since I just got my merged harness and goodies in the mail from iWire. Currently, I have all the parts on hand to throw into the car to complete the swap, minus a Cobb downpipe which is on backorder for who knows how long. It seems like set-backs are par for the course for this build. I'll keep everyone updated when I'm back in the garage!
 
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