2002 "BUG WRC" STI [The Revival]
 

Hi All,

I hadn't posted before regarding my 2002 Impreza WRX STI [BUG WRC] but thought now with the rebuild post engine failure this would be a good way to track rebuild progress.
[IMG]https://i.imgur.com/K0ywF5c.jpeg[/IMG]

Long story short last year I blew up the ol' faithful original EJ207 after what i suspect was a waste gate failure, either caused by the boost controller or a vacuum leak, sending 35+ PSI through the motor popping the HEaD GaSK3t and subsequently overheating cylinder 4 before a rod got bent calling it a day.

Cut to the present and I've spent the last year building the new and very potent motor to propel the BUG into the next space balls galaxy, which apart from some small ancillary bits and pieces is complete. Additional plans now on the "while we're here" list include a rotated turbo, reverse mount intake, ABS delete, electric power steering pump install, engine bay shave to name a few things.


[*New* Engine]
New 2.5L Short Block
Michael South Cross-flow Drilled Crank
Close Decked & Pinned
ARP Custom Age 625+ Head Studs
Argo I Beem Rods
CP Forged Pistons
ACL Race Bearings
STI #11 Oil Pump (Ported)
03 Spec C 2.0L Heads (Single AVCS)
Ported
Spec C Cams
BC Valve Springs & Titanium Retainers
Torque Solutions HD Timing Belt Tensioner
Killer B Sump, Pickup & Baffle Plate
+ More

[Engine Ancillaries]
Aeroflow [Size not chosen] Turbo
Killer B Holy Headers [Modified to V Band]
PSR Up-Pipe [Modified to V Band]
Invidia N1 Exhaust [Modified to V Band]
ID 1300 Injectors
Radium Fuel Rails/ Custom Lines
+ More

[Engine Control]
Link G4+ ECU

[Suspension]
MCA Purple Coilovers
Whiteline [Entire Catalog]
+ More

[Driveline]
[TBD] Twin Plate Clutch
Cusco 1 Way Front Differential
Cusco 1.5 Way Rear Differential
Cusco Rear Differential Cover
+ More

[Interior]
AGI Bolt-in Half Cage
Velo GP90 Seats ("STI" Embroidered)
Nadri 350MM Deep Corn
+ More

Big targets with the new build but I'm taking my time, making sure everything is up to task and being fully ready to send it.

I'll post more updates are the build progresses.

hey man, we have met at motorplex drags. i have the "drewgong" hawk sti.[YT][/YT] love what you've done with the motor, will definitely hold power! lots of good stuff hanging off it too. interested to see where you go with this!

Thanks - Here's hoping it makes around 500 HP to all four wheels. Next step right now is getting a 2.5i intake, shaving it, painting/powder coating it and then making it fit without the injectors and AVCS solenoid kissing each other and a massive spacer.

Keeping the updates rolling through I've now got a 2.5i intake which needs to be shaved down, port matched and powder coated. Most of the bolt holes will go if not all but the fuel rail, intake mount and throttle body mounts and possibly the harness routing bolts underneath.
[IMG]https://i.imgur.com/SoK2DI5.jpeg[/IMG]

The common issue with running the 2.5i intake is that the injector angle is more down (say ~45 degrees) than any STI manifolds (~50-60 degrees), which becomes a problem with the AVCS solenoid hitting the fuel rail. This thread shows how others have solved this issue [URL="https://forums.nasioc.com/forums/showthread.php?t=2623604"]https://forums.nasioc.com/forums/showthread.php?t=2623604[/URL].

To be different I'm not going to using the massive 18-20mm spacers out there and instead will just use a 3mm (as i already had one) and then trim the connector off the solenoid and add my own pig tail into deutsch connector. Just using pliers to trim off the connector upper shell it's already flush with the top of the solenoid, and bending those pins 90 will get some clearance.
[IMG]https://i.imgur.com/fdaSDBK.jpeg[/IMG]

This is an old spare solenoid so soon I'm going to continue carefully removing the connector with a dremel and get even more clearance. After all this the pins will be soldered to some extension wires, potted and hi temp heat shrunk.