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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #1 (Edited)
Motor:
USDM STI EJ257
Mahle 4032 pistons
ACL main and rod bearings
STI Nitride crank
Nitride’d valves
3 angle valve grind
Gates Teflon timing belt
JDM STI flywheel
Exedy Stage 2 clutch


Performance:
Ported and polished VF39
TurboSmart IWG
GrimmSpeed EBCS
GrimmSpeed TopMount
DEI Reflct-a-gold heat wrap
Silicone turbo inlet
All rubber replaced with silicone
PTP Turbo Blanket
Fujita Short Ram intake
SRS catless downpipe
HKS resonator/Flowmaster muffler
Walbro 255
Running Cobb Stage 2 – waiting on E85 ProTune
Cosworth radiator caps
Grimmspeed Air-Oil Separator

Suspension/handling:
V4 STI 4.44 transmission
FXT 4.44 rear diff
WRX slave cyl/stainless clutch line
Aluminum control arms
JDM Type RA Spec-C 4 way adjustable struts
SPT blue springs
Whiteline 20mm sway bar
EBC RedStuff pads
StopTech stainless steel lines

Misc:
Defi boost gauge
PIAA horns
Beatrush pulley cover
V4 STI Momo steering wheel

Upcoming:
USDM 2004 STI steering rack + bushings – needs to be installed
E85 protune
Modded sidefeeds
Oil catch can
4/2 pot brake conversion
Aluminum radiator w/ slim fans



 

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Registered
2000 Ej257 swapped 2.5rs
Joined
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83 Posts
Discussion Starter #3 (Edited)
Been a busy few weeks since I bought the car. Got the following in the mail recently:

V4 STI 5 speed 4.44 trans, 70k miles
R160 4.44 LSD from an auto 2.5RS
V4 STI short shifter
V4 STI flywheel
V4 STI axles
V4 STI front crossmember
V4 STI Momo steering wheel
V4 STI center tach/8k cluster


Getting the flywheel resurfaced, and waiting on Exedy OE clutch, 02 WRX slave cyl, and 02 WRX braided clutch line in the mail before the trans goes in.

In the mean time, swapped out JDM 1 cat DP for USDM 2 cat DP and took it to BAR ref. It failed because he needed to pull the VIN off ot the ECU but couldn't (mild tune) so that's probably why, but he also said that he needed a calibration number to indicate that it's an ECU from an 04 STI; I was just going to reflash it to stock... Can anyone shed some light on this?

Also was classified as a 'gross polluter' which was traced to a bad rear 02 sensor thus running really rich, which was actually a resistor wired inline to fool the ECU by the previous owner (lame). Fixed that and I'm having some hesitation problems that I think can be traced to the tune; also going to replace the plugs which are likely fouled and clean the MAF.

Traced down an oil leak to bad valve cover gaskets... not sure why they're leaking with only 6k on the engine, but they're getting pulled and redone when I get the trans out.
 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #6
Thanks guys! Z1 should be shipping the clutch around Thursday and the trans should be in by Monday. Excited to have a torquey 4.44 to drive around town. And yeah it'll stay sleeper, at most I'm looking at a respray but it's real nice not having to worry about scratches/door dings/snow banks/etc
 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #7 (Edited)
After a few weeks of hassling with my bank, got the final packages in the mail
  • Resurfaced stepped flywheel
  • 4.44 R160 w/ LSD
  • WRX slave cyl
  • WRX clutch line
  • Exedy clutch kit
  • 4 qts RP 75w90/ Subaru LSD oil
  • Cusco rear strut brace
Everything's ready, car is on the lift at Boosted Tuning and we should have the trans in by Wednesday!! Aww yeahhhhhh :drunk:
 

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Free!
01 RSTI / 03LeggyH6
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6,933 Posts
Nice! That Motor should last a good while. Same formula used to build mine (Also a GT car) and mine's going on 5 years strong and I beat the piss out of it. :) My engine builder no longer works there though but I'll bet he built that motor.
 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #9
Nice! That Motor should last a good while. Same formula used to build mine (Also a GT car) and mine's going on 5 years strong and I beat the piss out of it. :) My engine builder no longer works there though but I'll bet he built that motor.
Yep! Same person. Just curious, what oil did you run before/after break in?
 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #12
Castrol Synthetic at first then it's always been running Motul 8100 5w40
Ok cool. Yeah I'm pretty stoked for the motor, I've been running around with only 1st, 2nd, and 5th gear... I've had another car to use in the meantime because it was pretty much undriveable. Also excited for 4.44... should be an animal
 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #13
Got the car back today, after about a week longer than expected in the shop due to failed clutch master cylinder, missing oil line clamp, etc etc. New master cylinder and some new fluid later, and it's running and driving perfectly on a a stock 04 STI rom. Having some sputtering at WOT, usually in the top of 3rd, but I think I need to let the ecu learn a bit more and clean the MAF. This car is absolutely ridiculous with 4.44 rear.

Now on to suspension, just ordered sway bar/endlinks, just got the rear strut tower brace in, and I'm looking around for a set of struts/springs.

I'd post some pics but re25.com\uploads gives me an error and apparently there's an upload limit for any given thread...

 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #14
Diff cleaned up a bit... more pictures of the trans swap soon.


Also had clutch issues, after the clutch master cylinder was replaced and everything was bled, the car was left on an incline and the clutch would stick to the floor. Let it sit on level ground, and adjusted this stop/clutch pedal position sensor and everything was good.

Also, the new rom is from an 04 STI (as opposed to an 04 FXT, which was on there already), I'm now getting a CEL for the neutral position sensor. I'm pretty sure all of the trans sensors were swapped over OK....

 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #15
Yeah, the code I was getting is for the E-Brake 'parking sensor' light, weird that that throws a CEL....

Still having clutch issues if I leave the car overnight. Clutch pedal only has resistance for like half of its travel, and I have to pull the pedal with my toe to get it to return all the way up. After I pump the clutch a few times, it works fine. Master cylinder/slave cylinder/clutch line are all brand new. Any ideas?

Finished up some work this weekend as well... Just finished break-in on the engine and did the first change with Rotella T6, car runs like a dream. Having some hesitation/fuel cut issues but they a. seem to go away as the ECU finishes learning and b. I think they're related to running a Vf48 on a stock tune but we'll see. Just have to get it to pass BAR as soon as possible and then I'll deal with all of these. Sway bar/endlinks/ manual boost controller in the mail... just about to order some struts and springs ;)



Nice to have a garage for a bit....



Also very nice to have intact axle seals!



Swapped the plugs over for NGK LFR7AIX. Had to get creative with this plug.



Cleaned up corrosion and replaced both battery terminals.

 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #17
Incognito (for now). Fully 3 inch with a Flowmaster and 1 HKS resonator. Resonator coming out once I pass BAR to open up the sound quite a bit.

 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #18
Ugh, got another oil leak today. Pulled the ball joint off and replaced the clip for the oil return line from the bottom of the turbo. Looks like it broke because there's no mounts holding the turbo on - it's just being held in by the uppipe and downpipe.

Fixed a leak from a through bolt on the side of the trans.

Getting a weird leak from the axle seal - I think it's a crack in the side of the axle end that's leaking grease or something.

Put on an AC belt and charged up the AC, doesn't blow cold yet but I think I need to cycle it a bit as it hasn't had cold air through it in a while. Belt squeaks though because the tensioner is all the way at the bottom - need a smaller belt.

 

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2000 Ej257 swapped 2.5rs
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83 Posts
Discussion Starter #20
KYB AGX struts, SPT springs, Whiteline 20mm adjustable sway bar, Whiteline end links, prothane bushings, and Hallmann boost controller arrived today
 
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