'08 BL9 2.5i. '91 BC6 awd and turbo conversion.

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'08 BL9 2.5i. '91 BC6 awd and turbo conversion.

Postby rexhunta » Mon Feb 15, 2021 7:58 pm

Hey guys,

Thought I would put some of my car up here.

I sold my heavily modified TJ Wrangler late last year as I was only going out wheeling twice a year, so was a waste to leave sitting in the shed all the time.

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And I ended up purchasing a '08 gen 4 2.5i which I believe is the facelift model with projectors and the sweeping dash, 4at at the moment.

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I have had maaaany modified jap imports ranging from an RVR, to S13 silvias, and just miss being able to scoot out when I want, without getting covered in mud and crap.

Anyway, It is a completely stock gen 4 when I purchased it, atm I am half way through turbo'ing it. I have a spare EJ20 from an '05 wrx that I am going to build up in due course when I manage to blow this up. I am only chasing 5-6psi on the stock ej253, nothing too fancy, just miss the noises and fun. Plus, getting to spend shed time has been great to get my mind off things that have happened over the last couple of months.

anyways, here's a few photos.

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china headers into an up pipe I fabbed. I autocad'd all the flanges I needed and got the local laser cutters to get them cut and sent back. All wrapped in HPP wrap. I have a gt crossmember which all fits so snuggly against the single cam head with only a couple of mm spare. Can also see the hardline that goes to the sump for oil return.

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rather basic dump pipe, with a 200 cell cat at the end. all the piping is 2.5" for this setup, as I said, I'm not looking for massive power or anything. It's only a td04l.

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Intake side sorted apart from adding in a few fittings for breathers. I am going to run a catch can setup. I have the check valve to install still for the brake booster as well.

Also need to remount my coils, and extend the o2 sensor for the back of the cat as it's moved to under the car. Also need to remake the bracket for the waste gate actuator as I have clocked the turbo a fair amount.

I still have to make all the intercooler piping, I have a small 550x200x50 fmic to go on, and then working out some fuelling side. When I build the next motor I'll go onto a haltech or similar.

Pete.
Last edited by rexhunta on Wed Mar 16, 2022 6:33 pm, edited 2 times in total.
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Re: '08 BL9 2.5i.

Postby Yowie » Mon Feb 15, 2021 9:09 pm

Good work!

I know Gen 4 GT's are getting hard to find, but turboing an NA model is pretty dedicated.
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Re: '08 BL9 2.5i.

Postby nvmylh » Mon Feb 15, 2021 9:34 pm

Good on you giving the turbo-NA route a go! I turbo'd my ej251 outback over a year ago now (link below) and it was the best thing I ever did to that car! Still runs really good, I reckon it would give my ez30 gen4 a hell of a run for its money!

I used the same intake manifold as your car and fitted blue sti injectors (550cc), not sure what you're planning on doing for tuning etc?


http://www.subyclub.com/topic/9637-gen- ... converted/
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Re: '08 BL9 2.5i.

Postby rexhunta » Mon Feb 15, 2021 10:27 pm

later date a 1500 or 2500 haltech, although I have been chatting with a guy in Perth and some other stuff has been coming about which does look promising.

Car does not owe me much, and being an older fellow I prefer the tinkering, and having 3/4 of the bits laying around in the shed from other projects over the years, If it blows, it blows. I'm not entirely fussed.

If it doesn't ever come to fruition I have all the stock gear sitting on shelves, a days work and it can be completely NA again.

I built the up pipe out the car, I have an ej20 with a spun bearing, I found some spare 253 heads on marketplace with all the sensors attached, and built all that section on the engine stand. made life a lot easier then dropping the crossmember 1500 times while trying to lobster back up and around the sharp corners of the head.

I am only planning on 5 psi on this motor, so anything basic will do me fine.
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Re: '08 BL9 2.5i.

Postby Yowie » Tue Feb 16, 2021 8:30 am

5psi on a higher compression engine would be very responsive and loads of fun (without needing fire hoses for injectors).

Not exactly a scientific test, but on my car & tune (E85 etc) I've noticed that I can get to nearly 5psi while still running a stoich air-fuel ratio before it tips into "rich".
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Re: '08 BL9 2.5i.

Postby bigBADbenny » Thu Feb 18, 2021 9:18 am

Love it! Keep the updates coming! :good:
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Re: '08 BL9 2.5i.

Postby nvmylh » Thu Feb 18, 2021 12:45 pm

Have you checked out Project Lambda Tuning? I'm not sure if they can do your engine but I think the guy just updates his software whenever he gets a request.

I used it on mine, works pretty good, way cheaper than a haltec and perfect for these jobs.
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Re: '08 BL9 2.5i.

Postby rexhunta » Thu Feb 18, 2021 10:54 pm

nvmylh wrote:Have you checked out Project Lambda Tuning? I'm not sure if they can do your engine but I think the guy just updates his software whenever he gets a request.

I used it on mine, works pretty good, way cheaper than a haltec and perfect for these jobs.



I’ll have to check them out. I have to talked to a bloke in Perth who has worked out the tuning side but said it’s pretty hard to check still, so will check it out.

I got the oil feed line made by Pirtek in stainless braided with Teflon inner, and jic fittings on each end.

Picked up enough to bends to start the intercooler piping, mounted the cooler the other night.
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Re: '08 BL9 2.5i.

Postby Turbo Lag » Tue Feb 23, 2021 7:16 pm

Very impressive effort here, can't wait to see the end results of this. Can't say I've seen a 4EAT 2.5i with forced induction before. :shock:
'04 Subaru Liberty 2.5i Safety Pack Sedan 5MT & '08 Subaru Liberty GT-B Tuned by STI Wagon 6MT & '00 Toyota Altezza RS200-Z 6MT & '16 Honda CB500F
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Re: '08 BL9 2.5i.

Postby rexhunta » Tue Feb 23, 2021 7:50 pm

Thanks. I don't really think I have either.

Intercooler and all the pipes are all made and in, intake side is done, I just need to make a mount for the AFM like they do with the LS and then a couple of bungs and sort out the catch can side.

Few more small parts turned up like heat sleeves for the oil return and a filter. Going away for a few days but hopefully tomorrow evening I might head up and get some other small stuff done if I get some time.
rexhunta
 
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Real name: Peter

Re: '08 BL9 2.5i.

Postby rexhunta » Mon Mar 01, 2021 6:56 pm

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Intercooler side done. Hoping by going into a 2.5" I create a little lag and not hit on the rods so hard with the pressure.

Hopefully with the weather we're about to have here I can get off a little earlier next couple of days and get a mount made for the coilpacks on the passenger side of the throttle body, flip the leads around and extend the plug.

Also in that time need to mount the AFM into the intake pipe and probably smash a couple of tabs on, make some sort of divider from the engine.

Got a small design drawn up for a double sided catch can, on my to do list too when I have 5 mins, going to put it into cad and get it sent off to be cut.

Pete.
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Re: '08 BL9 2.5i.

Postby nvmylh » Tue Mar 02, 2021 7:55 am

Coming along nicely! You reminded me that I should get around to painting my intercooler pipes!

If its of any use: I used the same style intake manifold and coil pack, but relocated the coil to just above the cyl. 1 (or 2?) runner on the manifold, up behind the powersteering pump. Was able to use the standard leads then too.


20200331_12273 0.jpg
20200331_12273 0.jpg (240.35 KiB) Viewed 6195 times
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Re: '08 BL9 2.5i.

Postby rexhunta » Tue Mar 02, 2021 12:23 pm

nvmylh wrote:Coming along nicely! You reminded me that I should get around to painting my intercooler pipes!

If its of any use: I used the same style intake manifold and coil pack, but relocated the coil to just above the cyl. 1 (or 2?) runner on the manifold, up behind the powersteering pump. Was able to use the standard leads then too.


20200331_12273 0.jpg


I had wanted to put it in front behind the alt but it’s too high. I’ll have a look at your position, but I’m majorly thinking passenger side and have it basically same position as the factory but flipped.
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Re: '08 BL9 2.5i.

Postby bigBADbenny » Tue Mar 02, 2021 12:25 pm

Here’s that knock sensing ignition retard box I may have mentioned.

http://www.jandssafeguard.com/
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Re: '08 BL9 2.5i.

Postby rexhunta » Tue Mar 02, 2021 3:10 pm

bigBADbenny wrote:Here’s that knock sensing ignition retard box I may have mentioned.

http://www.jandssafeguard.com/


Uh no you haven’t sorry. But definitely a good product
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