Subaru H6 EZ30 conversion

[toomanytoys]

PM coming your way...

[Shaundon]

Well the company that was supposed to be supply the engine crane contacted me to say it was stuck at the docks and they were hoping to get it out by the end of the week!

While i was waiting i managed to get the exhaust off with a bit of heat to the nuts and an impact driver. Had to cut through some of the rear bolts but managed to get the studs in the engine block off ok (phew , didnt fancy drilling them out if they snapped) .
Why can we put a man on the moon but we cant make exhaust connectors that dont rust away.

I was originally thinking i could use the cat from the subaru and fabricate an exhaust round it to fit the t25, but looking at it (its in 3 parts) its not gonna work i dont think.



So i guess i can cut off the flanged exhaust port connectors at the red line and fabricate something else for the t25. Not sure whether to bother with a CAT now? What have others done about the exhaust / CAT.

Started pulling the loom out too. The engine side was dead easy and have that all pulled out ready to go through the bulkhead when i can sort out the other side. Other side looks alot more complex however and ill have to get the majority of the dash off to get at it.

looking at the ignition area and fuses under steering wheel


i can see the ecu but cant quite get to it yet (under dash on drivers side)


need to work out what of all this lot i need to keep and what needs pulling through bulkhead (not sure yet if better to take engine wires into cab or other way about)

on the up side i found £3.20 behind some of the panels i removed on the dash!

[jes*b]

As I recall you should strip everything from interior more or less back to the bulkhead . The loom as you have seen is a monster and is basically a loop. You need to strip all the relays from the box in passenger side of ( bay) and pass it all inside through the grommet hole. A partner in crime is best at this stage. If you spend an hour or so gutting the interior you will have room to breath. Watching with interest. My H6 is on a pallet waiting to head to Dai's at some point. I dropped it with gearbox attached and split it after. I also cut the exhaust where you indicated but in situ. Cheers

[Shaundon]

so i have the engine and gear box out (pics to follow) and it seems there are two speed sensors on the automatic gearbox (circled red) that feed back to a connector on top of the gearbox along with another wire that goes down to the valve chest



do i keep these sensors ? if not can i just discard that part of the loom that goes to the sensors

if i do keep them i guess i need to attach them to something on the t25 - or attach another compatible speed sensor, perhaps to the drive shaft somewhere?-

anyone know what kind of signal these sensors produce and why are there 2? I guess I should have tested this when the car was still running!

[Shaundon]

ok seems there are 3 sensors 2 speed and 1 turbine speed
looks like i need to make the TCU(transmission control unit believe its in drive)
some good info here

http://www.rs25.com/forums/f145/t155496 ... -swap.html
and here
http://sl-i.net/FORUM/showthread.php?13169-EZ30D-Wiring

E D I T-
Just heard from Richard at RJES and he says just to remove the TCU.

I guess i still need a Speed signal to the ECU though...

[Shaundon]

Some pics of the engine coming out

I hired an engine crane from a guy up in surbiton at the very good price of £10 a day - if anyone needs an engine crane id recommend him (PM for his details)

coming out the top would have been easy if i hadn't missed a bellhousing bolt hidden under a wiring bracket. As a result i was hammering for ages trying to separate engine and bellhousing before realising my error. In my defense all i had read on the net said it was really tough to separate them so i just assumed this was normal!!


I lowered it onto a home made trolley



I designed the trolley so that the engine was sitting both on the engine mounts and some blocks of wood under the exhuast header mounting points (only flat part under the engine). This way i should be able to service it and access covers and gaskets while on the trolley.


I also added some more wood to support it while transporting the trolley - just as well i did as wheeling it along road to my back garden it hit some gravel and the wheels came off!! luckily the engine stayed on the wood structure.

engine out i had to remove the auto transmission as ive sold it on ebay - used a ratchet strap to stop it just falling out the front


and a jack under the diff at the rear of the transmission to lower it onto another dolly


So back to dismantling the dash removing the loom now.....

[Shaundon]

Well getting this out was a job


just some of the fixings i had to remove


whats more most of them were hidden and in hard to get at places
I just started pulling and undoing anything i could see until it eventually came out

if your doing this yourself then have a look at this video cause the centre console is a b#*!# if you dont know where these screws are
https://www.youtube.com/watch?v=03vuFKbC1sI

this is what im now left with!!!


what have i done!!!

[Smiffo]

Do you have all of the loom out that you need now?

[Shaundon]

no - still picking it apart and working out whats what . hopefully get it all out of the car this weekend

[Shaundon]

Ok - finally got the wiring harness out and sorted

ended up having to pull even more of the dash out till there was nothing left bar the wiring

heres the front of the car with everything out bar the bulkhead wiring harness - this is then pulled through the holes circled in red.


although the one on the far left routes through to the engine bay under the wheel arch to the main fuse box , you need to remove the plastic liners on the wheel arch to get at this and disconnect the main fuse box and feed through the hole in the engine ebay (circled red here)


and its finally out

I also removed the front wiring harness which loops round the front of the car by the radiator , although in reality after having studied the wiring diagrams i only really need the main fuse box and a few other bits from this.

[Shaundon]

well i plonked the wiring harness on a bench in my shed and stood looking at it for 10 mins wondering where to start

eventually decided i needed to get all the tape off to get at the wires so i could remove whats not needed.

there was quiet a lot of tape !


This left me this...


i decided the best way to tackle this was to start removing all the connectors i didnt need and tracing the wires back
after much studying of the wiring diagrams and many hours(days even) work i managed to simplify it all to this which should be everything i need

(doesnt include main fuse box but i may remove that and just wire a smaller fuse box up independently as very little in it i need)

and heres a shot of everything i removed (well some of it)


in hindsight it might have been easier to go with an aftermarket ecu such as mega squirt and save all this hassle , i just hope it works now.

Theres a few inputs and outputs from the ecu (or ecm as subaru calls it) that i still have to work out how to wire up but on the whole it should be good to go (such as connections to air con etc that are now just trailing wires).

Going back to doing the engine / gearbox next....

[Tinium]

And I always think I've done a good job when I wire a car stereo up... good work!

[Shaundon]

H6 on ebay

http://www.ebay.co.uk/itm/2003-SUBARU-L ... Swr7ZW7Fc3

going cheap - 1 hr to go.....

if anyone else fancies a go

[Shaundon]

Just done a compression test on the subaru engine and it reads about 170-180psi on 4 cylinders and 180-190psi on the other 2 (1+3) . The specs say 176 all round
although that is on a warm engine.

Does this sound like something I should be worried about?
What difference would doing it on a warm engine make?

[Shaundon]

ok just re read the specs and that was for a H4

figures for H6 are

Compression (350 rpm and fully open throttle):
Standard; 1,275 — 1,471 kPa (13.0 — 15.0 kg/cm2, 185 — 213 psi)
Limit; 1,128 kPa (11.5 kg/cm2, 164 psi)

Which suggests my figures are down a bit on that - i'm hoping that's because it's cold?

Will get it on the engine stand tomorrow and have a look over to see what i can see...