Hereby first part of my project trying to get the EJ20
drivetrain out of a 1991 Legacy 2.0 liter turbo and in my 1986 XT.
Already posted some info on a Dutch Subaru forum, but since probably your Dutch isn't all that, will do the English version here:
...Please feel free to comment, ask or criticize...
Bought my donor car late October this year, drove it for two weeks just to get to know the engine and drivetrain a bit and check for errors (and of course, experience the claimed 200 horses in this superstation
) , but found nothing really serious:
- was not very fuel efficient (but so is the XT, kind of expected that)
- at idle, engine 'rocked' a little. According to seller who was a mechanic, caused by faulty/sticky hydraulic lifter.
- some vibration could be felt in the steering wheel when braking.
- when starting, engine needed a few revolutions before firing up.
These things I will attend to later, for now everything seemed in good enough condition to go ahead.
My donor Legacy:
My XT in sorry state waiting for better things to come:
The engine fits with some minor slotting of the XT turbo crossmember.
For the transmission some modifications are needed for front crossmember. With the Legacy transmission using two crossmembers, best option is to custom make the rear one. Here's my build:
front crossmember: drilled two extra holes to accommodate the Legacy support. For reinforcement, positioned in a bushing in the now obsolete center hole and welded upper and bottom side to crossmember.
For some extra clearance, cut a little out of the rear side and welded everything back together:EDIT: Better to use a XT6 front x-member, that I installed later and is a better fitment. For a 1987 and later XT turbo, you can use the front and rear tranny x-member and use the EJ center section. For pre 1987 XT trubo's you have to fabricate a custom rear x-member which I also did.
For the rear I designed my own crossmember and had it lasercut out of 6 mm steel. It would be even nicer to have it made out of one piece and have it bended to get the little extra height.
and some pics from under the car. Have to weld the pieces of the rear crossmember, but it seems to fit nicely.
Although I share the opinion that the EA82 will have enough cooling capacity to cool this engine (especially in the not so very warm climate Holland has got to offer), my EA82 radiators are all completely shot and a new one is pretty expensive, whereas you can buy a used Legacy one for very little in the junkyard. Also because of the diameter difference between EJ20
and EA82 coolant tubes (38 vs 30 mm), I've decided to fit a Legacy (non turbo) radiator.
Rewelded the pins on lower radiator support so it fits in the holes of the XT body. The drain pipe now actually lines up with the drain-tube-hole.
Also lowered the lower radiator support a little and shaved a bit of the support rubbers, just to get a little extra clearance between radiator and hood.
cut and rewelded supports of lower radiator support:
To fit the radiator nicely behind the front of the engine bay, I drilled/grinded of the supports for the hood support thing. To use the Legacy upper radiator supports, I made two spacers to get them lined up properly
notice that because of the non turbo radiator I'm using I now have two thermostats.
The original Legacy radiator hoses can be used if you cut of a little at the ends
I relocated the XT hood support to the right and used one of the original Legacy radiator supports to keep it located when not in use (the yellow clip on the far side)
because not enough space is left between engine and radiator to fit either the Legacy or XT fan, I decided to modify the XT fan and mount it in front of the radiator. To go from a suck-through to a blow-through set up, had to modify the fan shroud a bit.
Cut out the fan supports, straightened them and with some cutting and welding fixed them back in to place. See pics:
and mounted on the radiator:
and in the car, fits nicely between the body parts of front of engine bay.EDIT: Later used a double push through fan of a Peugeot 206, better fit, less work. see later this project
air filter housing
nicest option for me was to utilize the bottom half of the XT housing and the upper half of the Legacy. Now I can use the original XT housing mounting holes and with the Legacy top half, get the MAF sensor pointing the right way. Only thing is that the XT uses these clamps to hold the halfs together, while the Legacy one is clamped by four bolts. Luckily the old XT one is made out of steel, so I welded some tabs on it with some weld nuts underneath.
Regarding position of air box relative to engine, the original Legacy resonator box doesn't line up anymore because it has an offset between inlet and outlet. Now the elbow after the MAF and engine inlet are in a straight line, for this I'll order the tube from MRT.
tabs on XT filter housing:
mounted in car:
MRT connection piece:
So, that's what's been done so far, big post but you're now all level with the current state of the project.
What's next to do:
- have found someone who'll ream my front lower arms to Legacy pin size since Legacy hubs utilize one size bigger pins (no XT6's here in Europe to get parts from...). It is only a increase of 2mm in diameter and I found there's quite a bit of material to safely enlarge these concical holes a bit. Will get them back before christmas.
- ordered a set of SuperPro poly bushings to freshen up all rotating points of front and rear suspension.
- mounted the air-to-water intercooler but now (as expected) I have some clearance issues with my wiper motor. Maybe I can use the Legacy one as its much smaller or get my hands on a right hand drive XT wiper motor. Moving the mechanism to the right side of the car will probably work.
Otherwise buy a used intercooler from an Impreza (they're smaller I believe) or go to a front mounted intercooler setup as Lazer has on his EJ20
- work on the hydraulic clutch set up
- get some info on different brands of shock manufacturers and see what they have to offer on 2003,5 and up Legacy coil overs. From Suberdave;s GL10 build up this seems like a nice option.
- get some info for the rear hubs and conversion to 5 x 100 bolt pattern and get a handbrake working on those rear discs. See what Crossbred has to offer. Maybe someone here has got some info/pics what their kit includes. Might be a expensive option though, but will go for it if other options are unsafe or not up to standard.
Also read some about redrilling the original 4 x 140 hubs, again, any info is greatly appreciated.
- work on the electrics. Disassembled the Legacy dash and labeled all connectors. Now have to sort out what can be cut out and what needs to be transfered to the XT. Also, getting my XT dash to work with the Legacy drivetrain/sensors needs some thinking.
that's all for now, thanks for your input.