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Old 10 February 2006 | 07:10 PM
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Default DIY 450 bhp Classic 2.0L

Well having weighed up the options and all the pros and cons of each of those options I have finally decided on which route to take after my 1999 Turbo 2000 gave up the ghost last week.

As the title of the post suggests I am sticking with the 2.0L and have set a target figure of 450bhp. Now to some of you this may not be a big target but for me it is.
I am not a mechanic nor will my car be visiting any tuning company over the next couple of months. I am simply an I.T consultant that enjoys his car.

This thread will document the project from start to finish with all results posted at the end of it hopefully hitting my target figure.

Here's some background info for starters.


The car was moderately tuned (circa 360 bhp). Until last week atleast.

I almost correctly diagnosed what the problem was when my car failed during some spirited driving.
I had thought that the engine had run lean and holed a piston. Naturally I had assumed that this was on NO. 3 Piston. due to that cylinder being the last to fuel via subarus fuel rail arrangement.

After taking the engine out I was surprised to see that No.3 was in excellent condition as were No's 2 and 4. The damage had occured to No. 1 piston. I have no idea what happened as there is no damage to the dish of the piston.
The damage has ocurred on the top edges of the crown and to the piston skirts.

Here's a few pictures to start it all off


Picture number one is my first purchase. No longer wanted to hire one and thought it as equally econimical to purchase one of these and no the camper van isnt mine its my dads

http://www.scoob.co.uk/rebuild/firstpurchase.jpg

This allowed me to get to this state:

Appologies for the mucky engine bay this will change for sure!!

Notice the 6 Speed box already in place

http://www.scoob.co.uk/rebuild/engineout.jpg


I've skipped the stripping down photos as all the detailed ones will be when I am putting it all back together.

Here are some close up of the damage to Number 1 Piston:

http://www.scoob.co.uk/rebuild/pistondamage1.jpg

http://www.scoob.co.uk/rebuild/pistondamage2.jpg

http://www.scoob.co.uk/rebuild/pistondamage3.jpg



And so starteth my DIY 450 bhp Classic 2.0L UK turbo 2000 project.

Last edited by dazdavies; 10 February 2006 at 07:13 PM.
Old 10 February 2006 | 08:30 PM
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That damage is classic of det, and probably resulted in a bearing picking up
Old 10 February 2006 | 08:41 PM
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why dont you stroke your 2ltr engine turbo chice is going to be your main item for 450bhp and how much/less lag you get. 450bhp is a good figure as its the one i'm aiming around
Old 10 February 2006 | 09:04 PM
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so what are the basic building bricks for a 450 x something 2 liter?
Power is basically Torque x revs, so the greater the torque x a high red line = power.

What is your basic list of bits daz?

graham.
Old 10 February 2006 | 09:33 PM
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Good luck Daz

I am roughly 30 minutes or so from Donny, so if you ever need any major help, drop us a line.
Old 10 February 2006 | 09:35 PM
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Originally Posted by 911
so what are the basic building bricks for a 450 x something 2 liter?
Power is basically Torque x revs, so the greater the torque x a high red line = power.

What is your basic list of bits daz?

graham.
Hi Graham,
Heres the list of what I already have:

STI 9 Niterided cross drilled crank
RCMS WRC lead copper bearings
Eagle Forged Rods
STI 5 heads.
RCMS Lightweight flywheel
RCMS Lightweight engine pulleys
6 Speed Gearbox
Walbro 255 lph Fuel Pump
APS Cold air feed with quickshift racing filter inplace of K&N item
GT Spec tubular headers
TSL group A Down pipe
TSL decat Centre Section
TSL Firestorm backbox
Apexi Power FC ECU and commander
Full samco hose set

Parts I need to purchase

RCMS GT35 VF Hybrid turbo with P20 exhaust housing
GT 35 fitting kit
740 or 850 injectors
RCMS parallel fuel rail conversion
SX fuel pressure regulator
APS front mount intercooler
76mm Samco inlet
Andy's mapping (again)

That should just about see me there.

Tim no bearing damage they are all fine. Even managed to salvage my rods

Last edited by dazdavies; 10 February 2006 at 09:39 PM.
Old 10 February 2006 | 09:36 PM
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Originally Posted by P20SPD
Good luck Daz

I am roughly 30 minutes or so from Donny, so if you ever need any major help, drop us a line.
Thats really good to know mate. I'll probably take you up on that at some point
Old 10 February 2006 | 09:40 PM
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pistons arent on there and thats a really big choice plus lots of other things your gonna need which all mount up the £££££
Old 10 February 2006 | 09:41 PM
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Originally Posted by stevebt
pistons arent on there and thats a really big choice plus lots of other things your gonna need which all mount up the £££££
oops forgot those. I'm going for some high compression Omega pistons with a 10cc dish either that or I have seen some wiseco on a US website for a third of the price
Old 10 February 2006 | 09:43 PM
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omega
Old 10 February 2006 | 09:43 PM
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LOL no probs.

Re your injectors, you might try Lateral, who sell the new 550's which are modified to flow 800cc at 3bar fuel pressure. He probably has a good price on the reg also.

Steven
Old 10 February 2006 | 09:44 PM
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Lateral may also have some Wiseco's in stock.
Old 10 February 2006 | 09:45 PM
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spoke to Mark a couple of times now.

Will probably buying stuff from him over the course of the project
Old 10 February 2006 | 09:46 PM
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Originally Posted by P20SPD
Lateral may also have some Wiseco's in stock.
Not at the price I have seen them for.

http://www.importperformanceparts.ne...ns_subaru.html

K588M925 are the ones for me

£330 delivered including rings and pins and circlips

Last edited by dazdavies; 10 February 2006 at 09:49 PM.
Old 10 February 2006 | 09:48 PM
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Old 10 February 2006 | 09:53 PM
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Originally Posted by dazdavies
Not at the price I have seen them for.

http://www.importperformanceparts.ne...ns_subaru.html

K588M925 are the ones for me

£330 delivered including rings and pins and circlips
just be aware if you order the wrong pistons from a company like this your throwing your money away but if you ask marks advice on picking them you cant go wrong. cheaper isnt always better
Old 10 February 2006 | 09:53 PM
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Pretty sure those are the right pistons from wiseco
Old 10 February 2006 | 10:24 PM
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Originally Posted by dazdavies
Not at the price I have seen them for.

http://www.importperformanceparts.ne...ns_subaru.html

K588M925 are the ones for me

£330 delivered including rings and pins and circlips
They are nothing like the Wiseco's available in the UK, which are custom specced, with a different forging, dish shape, compression height, ring land spacing, valve pockets and taper.

No doubt they are all good pistons though.

Paul
Old 11 February 2006 | 08:15 PM
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AFIAK, Scoobyclinic also carry Wiseco's (sourced from Mark/LP?)
Old 11 February 2006 | 11:13 PM
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Daz, will be looking forward to reading this thread, hope its really detailed as no doubt i will have to follow the same route at some point as i begin to stress my relitivley well tuned MY99 along some more!

Dan.
Old 11 February 2006 | 11:17 PM
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Oh and shame about that inlet manifold, Parcel farce strike again
Old 13 February 2006 | 04:28 PM
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Originally Posted by Danny Boy
Oh and shame about that inlet manifold, Parcel farce strike again
Still on the case with that mate I am sure its in their fecking warehouse.

I going to go there and look for it tomorrow.

As for the thread it will be very detailed.
Just bought some 850cc Injectors on ebay for £150.

Quite pleased with that!!!

Last edited by dazdavies; 13 February 2006 at 04:30 PM.
Old 13 February 2006 | 06:50 PM
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Be warey of 850's they can be a pig at low engine speeds especially when trying to get a decent idle
Old 14 February 2006 | 08:28 AM
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I'm sure Andy will be able to map them accordingly.
Old 14 February 2006 | 08:38 AM
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just dont expect the smoothest/lowest rpm idle

850's are notorious for being 'granular' ... read up on 22b. Plenty there have been there and done it.
Old 14 February 2006 | 10:01 AM
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will be following this with interest, seems to be a few of us who will be taking the next step to approx 450.
might be worth looking at increasing the bore and stroking your 2.0 to 2.15?
possibly might be worth sourcing a cheapo CDB as well as with the gt35 hybrid it might require some hefty boost to make a good 450
Old 14 February 2006 | 10:53 AM
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I'm using a set of Lateral Performance modified 550cc injectors, which at 4 bar fuel pressure can flow up to around 860cc IIRC as well as being a flow and spary pattern matched set. Not the cheapest, but certainly some of the, if not the best injectors currently available for a Subaru engine
Old 14 February 2006 | 06:52 PM
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Originally Posted by Peanuts
will be following this with interest, seems to be a few of us who will be taking the next step to approx 450.
might be worth looking at increasing the bore and stroking your 2.0 to 2.15?
possibly might be worth sourcing a cheapo CDB as well as with the gt35 hybrid it might require some hefty boost to make a good 450
Bob Rawle's Car (2.0) STI5 has just made 488bhp /425ft lbs with one of these on.
I went in Dave Moulds P1 about 18 months ago and that was nice too. Same turbo with 850's on.

As for increasing the bore I am going for 92.5mm pistons (2nd oversize) so will be having a rebore anyway but no bigger than that.
Had my crank rod and bearings been knackered I would be going for a Axis performance 2.5 block they do these with a 9500 rpm rev limit.
But I have the STI 9 tuftrided, niterided crank, Eagle forged rods and RCMS wrc lead copper bearings so I'm sticking with 2.0L for the time being.

Last edited by dazdavies; 15 February 2006 at 03:42 PM.
Old 14 February 2006 | 07:31 PM
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Originally Posted by dazdavies
with a 9500 rpm rev limit.
Then you would be looking at a small fortune in heads to cope with it IMO
Old 14 February 2006 | 07:56 PM
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Originally Posted by P20SPD
Then you would be looking at a small fortune in heads to cope with it IMO
Which is exactly why I am sticking with the 2.0L.

A small update:
I have cleaned the donor 2.0L block halves today. Loads of chemicals a big jet washer / steam cleaner was used and its come up a treat. The bores started discolouring almost immediatly so they were rinsed dried and lathered in engine oil to keep them in good nick.
Pics tomorrow.

Last edited by dazdavies; 19 February 2006 at 07:53 PM.


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