279 replies to this topic

[Adam]

Awesome! Mine needs a refresh. Should've done the throttle body too

[duncanm]

awesome.  Black is the new red.

[Barbbachello]

[CRUISN]

Good color choice.

[Lukeoly]

I'm hoping someone here can help me figure out what to do with this mystery coolant pipe on the GC8 engine.

 

 

I can't remember where this pipe went when the old manifold was attached, but it appears to come from behind the timing belt (and down into the water pump housing I guess) and go under the intake and turbo inlet then come up through the intake runners on the driver's side.

The GD manifold has the TGVs in the way so there's absolutely no room for this pipe to come up through the intake like it did before.

 

Can anyone shed some light on where this pipe goes on the GC8 EJ205 and how it's done differently on the GD EJ205?

 

Pic without highlighting:

 

 

Passenger side routing:

 

 

Pic with the intake fitted:

[Beckers]

It goes to the alloy header tank, with the rad cap on it, I think.

[Lukeoly]

I've been searching in my lunchbreak and that's the conclusion I came to as well. It's really the only thing coolant related in that area anyway. 

Can anyone confirm if the GD plastic header tank has different pickup point on the bottom? I'd like to try and use the metal one from the GC8 if possible.

 

Here's a pic I found on legacyCentral showing the same pipe; updated to suit the TGV manifold (it basically goes straight up instead of coming through the runners on an angle:

[Cam.]

If it was a MY99-00, It will be the same as GD I think.

GD 01-04 used the metal header tank. The MY05's+ got the plastic fantastic unit.

[Lukeoly]

As Cam mentioned, Early GDs used a metal tank, and this is definitely a 99-00 engine. It had me stumped. 

After pulling the original manifold out of storage and test fitting the header tank I can now see what the go is. First of all, the GC manifold has heaps more room to move (mainly because of the side feeds and the fact that it doesn't have TGVs). The other thing I noticed is that the GC manifold positions the tank a little further forward. This got me thinking and after a little interwebs reaserch, I can confirm that the GC and GD header tanks are different.

 

The GC tank has the the outlet pointing rearward – mounting it further forward allows it to still match up with the pipe through the intake runners.

 

The GD tank has the outlet facing towards the engine.

 

You can see in this pic that the GD one on the right has the outlet pointing towards the mounting holes (i.e. inlet manifold)

 

Looks like I'll have to try and source another header tank and matching hardline :-(

[Lukeoly]

Update:

Morgan and I had a great day working on the lib today.
First thing on the list was to install the DeatschWerks 65c fuel pump.

It went so smoothly most of the time was spent removing the modified mount I had made for the Walbro. I'm sure glad I made it reversible!

 

Installed:
 

The pump install was so easy, we were feeling ambitious enough to get the gearbox installed. I was planning on installing the gearbox on the back of the engine but it's not ready yet so we decided to go for it.

 

 

We ended up pulling it in from the front and raised it into position with a couple of jacks. There was a little mucking around with the rear jack and the gearbox crossmember wanting to be in the same place, it went in without much hassle.

 

The gearbox is a 5 speed originally from an '06 WRX.
We used the Liberty gearbox mount (for now), crossmember and linkage.

Having the gearbox mounted, I couldn't help but test fit the dump pipe to check for any clearance issues. So far so good.

 

TURBO!!!

 

 

I seem to be collecting WAY too many parts without much space to store suff

[Morgan]

Such an epic day!

[duncanm]

Excellent stuff..   why so many gearboxes?

 

I see you managed a score on the braided clutch line. I think only potential clearance issue is that white firewall/rail bracket thingy.

 

and you can keep your hill hold!

[CRUISN]

Great work and even more so for doing it on the ground outdoors.

[Lukeoly]

Excellent stuff..   why so many gearboxes?

 

I see you managed a score on the braided clutch line. I think only potential clearance issue is that white firewall/rail bracket thingy.

 

and you can keep your hill hold!

 

Far gearbox in the pic is the original Lib gearbox, middle one is the original box from my old WRX (with a stuffed reverse gear, it's fixable so I've held onto it for now) and the one in front is the gearbox I replaced the broken one with in my WRX – it's the one that's now in the Lib.

 

I had read in the past that the white bracket caused issues so that got removed straight away.

I don't think those WRXs had hill hold (unless it's just something I never hooked up.

[Lukeoly]

Great work and even more so for doing it on the ground outdoors.

 

Haha. I don't have much choice at this stage. We were planning to do the swap in my Dad's shed but it's yet to be approved by Council and put up.

[duncanm]

 

I don't think those WRXs had hill hold (unless it's just something I never hooked up.

 

They didn't - its a lib/outback thing, I think.

 

But I miss it - a bit.  Not entirely, though, as reversing down a hill with the hill hold used to annoy the shit out of me.

[Morgan]

My Forester has it but sister's 06 Impreza (NA) doesn't?

 

Old man's 09 WRX did too but it was a different mechanism - only held for 2 seconds after releasing the brake. Gave me quite a shock the first time on a hill in traffic!

[Lukeoly]

UPDATE!

 

The wiring is going to AM Auto this week! 

We had a moment were Miles thought it wasn't going to be possible to turn the AVCS codes off in the JDM ECU. I promptly called Michael at MSR to get his thoughts on disabling AVCS. I was glad to hear that it's quite possible. Phew. For a moment there I was having to entertain the idea of having to source a AUDM WRX ECU with matching immobiliser and key chip – not an expense I had foreseen.

 

I lot can be said for using a front cut as these little compatibility issues can be avoided.

That being said, I'm always up for a challenge and I feel like I'm still ahead budget wise for using what I have already on hand.

 

I'm also planing a trip down to Ichiban this weekend to grab the following items:

If anyone has these items laying around and feels like donating/selling them to the cause it'd be appreciated :-)

- AFM (GD Type)

- WRX Airbox

- R160 Diff (4.444)

- Cam cover gasket set

- TD04 gasket kit

- Inlet manifold gaskets

- GEN3 Turbo bonnet

- '01+ WRX Header tank and pipe from tank to water pump 

[Lukeoly]

I packed up the wiring to send last night; trying to minimise sending anything unnecessary to avoid sending two boxes. I was pretty stoked to get both looms in the one box!

 

The one in back is the original Liberty loom and the one up front is the WRX loom. It's hard to gauge the size from a pic but it's clear how much larger the WRX loom is. Together in the box it came to a whopping 21KG!

 

[Morgan]

So glad Al is doing this and not us