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

[rexhunta]

Thanks guys. Definitely made a few people double take, the noise definitely does not match the car

[rexhunta]

So been cruising this a bit, here's how the engine bay looked.



Bought a few extras. ( Lucky a very good mate works at Bosch... worth going through him ! )



Done a bit so far. Pulled the Dash to get to the majority of wiring. All the Cruise control, leftover auto wiring, any sensors I didn't need and anything else I didn't want got properly ditched. If Subaru of the era made their harnesses like Suzuki did around the same era, would've been a hell of a lot less work Made a bracket for the DBW Pedal and sorted out a heap of wiring going wire by wire and making sure I document the lot.



Pulled intake manifold, replaced all the sensors I needed with the Bosch replacements and plugs, removed throttle body coolant lines, general clean up, removed other sensors didn't need.



Pulled the intake mani apart, deleted the IAC, removed the side feeds, had a look at the 3 sets of fuel rails I had on the shelf, and worked out to do a top feed conversion, I used the EJ253 rails, cut the FPR off and moved it right back towards the 3rd injector otherwise it would've been in the way of the intake of the turbo. Made a few more brackets to properly mount the rail solidly, replaced the injectors with Bosch 620s with new plugs to suit. Cleaned all the harness up, drileld and tapped new holes for the dbw throttle.



Started putting it together, made a few sensor adaptors and things, adjusted the fuel lines to fit in, using the Haltech internal map sensor with the Bosch air temp sensor.



and got everything together, laid in the harness in, started cleaning it up, need to modify the brackets for the coilpack cover so I can hide most of it again.



Unfortunately couldn't flip the throttle around upside down as it hits on the hydraulic slave for the clutch, so have to have it sitting up, unless I can work out a way to get a smaller slave clynder or being able to move it.

I've got the Bosch 3 bar map/air temp sensor that I haven't used, I figured for such a low hp number I'm better off using the internal map, but If I do, I'll move where I have made a bracket for the boost control solenoid and mount it inside the IAC blanking plate on the back of the manifold.

I've started to slowly change to the Haltech pins and plugs inside the car, i've made a massive excel spreadsheet of the haltech to subaru harness, which has helped, and i've gone through each factory subaru wire at the haltech plug and put the haltech colours under clear heatshrink with the pin numbers. Makes it more time consuming, but imho will make it so much better for investigating problems later if there is any.

Just waiting on Haltech to finish off making the next batch of wideband kits, guy who is going to be doing most of the tuning didnt want to use the AEM on the analogue inputs and wanted the WB-1 kit, so have ordered one, just waiting on it to come in.

Thanks Pete.

[Yowie]

Great work (and a lot of it). Cheers for the update with details.

[rexhunta]

Well, probably a slight update since then, I had it all working good for the 2 years, but got bored of the 9psi on the EJ22+t.

Late last year, I decided to give it a little bit. I had a set of Single-AVCS twin cam heads sitting on the shelf, so I sent them in to be decked. While these were away, I bought a new V7 207 shortblock, genuine gasket kit, 11mm oil pump, VF48 and syltech 3 port controller, Raceworks 1200s, aeroflow rrfpr, full timing belt kit/water pump/tensioner/idlers, and a heap of nickel and dime stuff like all the belt covers, pipework, hoses, oil lines etc.



I reused all the sensors, e-throttle. I cleaned up a stock EJ205 intake, serviced the heads after I got them back, polished and lapped the valves. I put the heads on with an ARP headstud kit for a bit of safety with the later model genuine MLS headgaskets. Also converted to single coilpacks, and added in a few sensors like fuel pressure/temp, oil pressure/temp, coolant pressure all into the ecu, as well as all the AVCS ins and outs. I threw in a PT Motorsport Canbus 4 port, PT Motorsport 12 I/O extender, and a CanChecked CanGauge.





Car has a run in tune at 18psi currently, and a spare map for 21psi which it will be left at on this turbo. It's definitely more fun to drive, and the weight the car is its great. I've got about 3-400 kms to go before i turn it up and then take it back to the dyno for a final figure.

BUT... I've also come across a dilemma. I have picked up an EJ20X with low compression, but I'm keen to drop the dual avcs heads into the car now with 272s in it. I think it'll be great combo with the VF48 for now, and then look to change to a bigger turbo later on. Decisions !

Pete.