I have now installed the turbo engine in my Forester. It was not an easy job, mainly because of the wiring issues. Along the way, I have installed new carpet and seats from an XT, a Hema HN7 and reversing camera, and a snorkel. What I can tell you is that the car goes exceptionally well.It has incredible torque and is so responsive.
The engine is from an MY07 WRX, which means it is a 2.5 litre engine with a TD04 turbo. I replaced the oil pickup, windage tray and sump with those from an MY99 WRX, as they are much stronger (the pick up that is). A new timing belt, water pump tensioner and pulleys, as well as a new thermostat were installed.
I am not a fan of DBW, so I instead to upgrade to a cable throttle. This meant a new throttle cable and pedal, new cruise control unit, new throttle body and a new manifold. All came off earlier version GD WRX's. Also off a GD WRX was the front sway bar. An XT Forester supplied the front cross member, radiator and bonnet, while an 06 STI supplied the power steering pump (which was overhauled), lines, cooler and reservoir. A GD WRX supplied the clutch master cylinder and lines. I bought a new dump pipe, but the rest of the exhaust i a combination of MY99 WRX, new resonnator and new catalytic converter.
By upgrading to a cable throttle, I could no longer use the factory ECU. So I instead purchased a Haltech Elite 1500, with wide band O2 sensor. The Elite is waterproof- which is ideal for off road applications. It also has knock control and launch control. I am still running the dual range 5 speed, but with the new turbo engine I needed a beefier clutch.
An enormous amount of time and effort went into the wiring. A lot less time and effort would have been required if the Subaru factory workshop manual was accurate, but for the most part it was wrong. I did countless voltage and continuity testing, but eventually everything was working.
A new engine meant that the airbox and ducting would change as well. It was the ideal time then to install a snorkel. I'd read of all the things needed to fit a Pajero snorkel on to an SG, but it was a lot easier than I was lead to believe. As long as you get the holes in the right place.
The carpet was in need of replacement. Unfortunately, during the replacement process the wires to the DCCD switches was damaged, so for a while I had no DCCD. this has now been fixed. The seat belt buckles mounted on the seats had changed since my model, so I had to quickly swap them off the old seats. Strangely, the poverty pack X model seats have arm rests, the newer, more expensive XT seats do not. Penny pinching from Subaru? Never!
With the bullbar possibly interfering with airflow to the TMIC, i decided to get a bigger bonnet scoop, and the one I got is a replica MY2 STI one. Geez, it's big and my mate I go away camping with, who is a little bloke, has some difficulty seeing over it.
Thing is, it climbs hill with complete ease that it previously would have struggled with. The car amazes with it's performance. It feels so much quicker than the SH XT I drove. Feels, but whether or not that is an illusion I don't yet know for sure.
