Derek's 93 NA to EJ22T wagon build

[turbo wagon]

First of all I would like to thank everyone who has contributed to this forum. There is a large amount of knowledge and wisdom documented for all to take advantage of to save these awesome cars from the junk pile.

I bought my 93 legacy wagon as a replacement for my wife's Volvo XC70 may it RIP. She was driving down US HYW 101 and had a catastrophic engine failure and had to be towed home. She had the next three days off work so I searched out and found the Legacy. Good deal on the price and not too far from home to go and get. I got the oil changed and let her have a go at it. not even a week later the legacy stopped running within a mile of where the Volvo quit. I thought it was funny, my wife didn't. anyways that is how I ended up finding this forum. I looked up how to change the timing belt and she was back on the road.

After that I found out what all you could do to these cars and started to get "Subaru envy". So once again I search for a EJ22T motor to buy and found somebody's project that they couldn't finish so I did. And that is the road I've been down for the better part of a year.

[turbo wagon]

I though I was buying just the EJ22T motor but when I got up there this guy had the whole set up, it came with:
two EJ22T short blocks
1 IM with all the sensors and full wiring harness
1 set of heads
turbo cross member
clutch kit
full 3" turbo back exhaust
front brakes
VF11 and TD04 turbos
boost gauge
catch can

and some other stuff I have forgotten, but all for the same price as what I thought I was buying just the motor for. so I lucked out and this has made the rest of the swap almost "free" compared to what I was going to spend.

[turbo wagon]

Here is the case halves bored 0.20 over with the crank/rods checked and forged pistons. what a beautiful sight!

[turbo wagon]

case halves together






Pistons in

[turbo wagon]

ARP head studs

Remember when you get your motor bored to have ARP studs with it so they can torque it down properly so the cylinder walls are round when you put on the heads. when I checked the roundness of the cylinders after the boring they were out of round when not torqued. I had to make a torque plate for the engine shop to do my motor.

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Head gaskets on





Heads all torqued down. looks good!

[turbo wagon]

I don't know where the pictures of the heads going together went but I had them decked and new exhaust valve with new valve guide seals.

I went with the Delta 220 grind cams.

I had to bleed the HLA's and buy two new ones. those things are pricy

Some people had problems with the lifter making too much sound with the 220 grind and had to put SS #10 washer under the HLA's to make up the slack. I turned the motor over when I had it all together and none of the HLA's had any movement to them so I let it ride to see if I need to do it later.

[turbo wagon]

Checked the oil pump for tolerance just for kicks, I was going to buy a new no matter what, I just have never seen an inside of a oil pump before.

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windage tray and sump on





Coolant manifold on

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cleaning the Intake manifold and wiring harness.

So I have a 93 NA wagon with the square plugs and the turbo harness was from a 91 with the rounds plugs so I got a NA harness from a 93 in a junk yard and moved the wires for the temp sensors. in this picture is the approximate location for the final harness wrap up.

[turbo wagon]

Changing out the EJ22T injectors for the 440 grey top injectors. Had the injectors cleaned and flow tested at witch hunter performance.

[turbo wagon]

running the coolant pipes. I used the NA coolant pipe from the heater so it would be in the right spot for the return heater hose. I planned on moving the location of the turbo coolant box away from the stock location so the engine bay is less busy with hoses criss crossing everywhere.

[turbo wagon]

Intake manifold on and running the PCV hoses

I had to get all new PCV hoses and yes I used the right ones so they won't crack.

I also put on the oil pump, water pump, timing belt with new idlers

[turbo wagon]

All put together. test fit for the intercooler and turbo




Here is the TD05 turbo
I went back on forth on which turbo to use. My motor came with the VF11 and a TD04. with the VF11 the oulet pipe was too high for the intercooler and the TD04 the inlet was funky with the 90 deg angle I had to put on there to get the intake right. this set me back several weeks. I then said screw it, I'm getting a TD05

[turbo wagon]

Pulled the motor and the NA cross member.
that cross member was a PITA to get out. I took it out with the steering rack in





NA and turbo cross members





put new boots and checked the tie rods on the steering rack

[turbo wagon]

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Here is the old and new exhausts

here is a great write up on how to put this in your wagon.

http://303lurch.com/?p=3

[turbo wagon]

I put on an 02 wrx wagon front 20mm sway bar with white line end links

[turbo wagon]

drilled grommet holes in the fire wall for all of the extra wires needed to run this beast. I ended up with like six holes.

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here is the wiring mess I had on my hands after running the Rob Tune ECU, Boost gauge, Oil pressure gauge, wide band 02 gauge, and a stereo.





In this picture I took out the cig lighter and found three of the wires needed for all of the gauges. There is a ignition on +, a ground, and a switched 12v on when the lights are turned on. that last one is needed for the dimmer for the gauges. I just relocated the cig lighter port to the center column for the cell phones.

[turbo wagon]

here is the thread for wiring in the Rob Tune ECU for my kind of swap

http://bbs.legacycentral.org/viewtopic.php?f=19&t=53163

[turbo wagon]

intake, BOV and PVC hoses

This took f...o....r...e....v...e...r... to run all of the hoses around the turbo and not kink. but all is well and each hose has it's place.

[turbo wagon]

Here is the video of the very first drive with the turbo swap!!!!!!!!!!!!!

It started up on the first try, broke in the cams for 20 min on high idle and took it for a drive

[kimokalihi]

Nice work! Looks like you're in oly? Me too. We should meet up sometime and check out each others cars.

[turbo wagon]

cool, when my schedule frees up I'll give you a shout out