My 330S build

Well ....

A year ago the 330S hatch was remapped by a very well respected southern mapper with the race rom map.
Loads of toys - launch control, in gear boost control, 2 fuel maps ( v-power and meths mix ), auto blip on downshift, and more. ( I took advice and ignored the mass density settings ).

I had ECUTek 800 cc/min injectors fitted at Litchfields on the way down for the mapping.


Afterwards there was a "hole" stuttering around 2500 - 3400 rpm ...
Several re-re-remaps later it was fixed, although that was achieved by adding 25% extra fuel in this map region, which seemed to affect the rest of the map / running range. Soot everywhere and los of 1/4 of fuel economy ... 18 mpg anyone!!!

Another even more respected mapper remapped the car and fixed the problem in a different manner.


The power levels were around 378 bhp / 400 lbft on v-power and 420 bhp / 460 lb ft on meths mix.


Then on a rolling road day the meths fuel only gave 360ish bhp ...
AND the engine spat out the radiator water.
It had a;so done this on the way back from the scotty map, and there were signs in the engine bay it had done so previously - splashes on the 2ry air pump and battery.



So I looked at several garages / engine builders.
I had used one birmingham based builder in the past and gotten bitten so was looking for some one more kosher.

One took my fancy as they had a great reputation and seemed to produce good builds and great power producing engines, as seen on the GR Hatch forum and Scoobynet.

Contact made, they said this was a job with their name on it .... meaning it was their specialty ( apart from 2.1 conversions! )


Soo off i went.

Car dropped off and starting to get engine out...



Nice to note that they clean the engine bay before the engine goes back in!

Dirty engines...

All sorts of bits came off..

This seemed like the culprit for the poor performance and stuff.






Broken piston land - common on the Hatch 2.5l

I fancied this mod ...



But cost wise and needed at my power levels .. not appropriate!

Some shiney bits...

Newly built short block ...

Heads after CNC work ...

Hmmm heads built up... sexxxyyy

So I am just awaiting the final build, running in and mapping of the engine.

The SC46 on a built 2.5l with no head work made 461 bhp, so with my heads I am hoping for a bit more!!
Lets say 480 bhp on v-power.
And some more to go on 16% meths / v-power mix ... HEHEHEHE

We shall see....

No, not planning on changing ECU ( unless I need to ) too expensive for the benefits. If I did it would be a Syvecs ( I think that was it ) but at £2000 not desperate to do so!

The headers were RCM - roger clark motorsport. As was the baffle plate and oil pump.
Mahle pistons, ARP head studs, ACL bearings, Cosworth "stopper" head gaskets,
I am afraid I agreed spec with Enginetuner and they picked the most appropriate parts .. I was not really gonna go for headers and FMIC... but while it's in .. feature creep sets in!

It seems now that there is no fitment for an uprated fuel pump for the hatches ( RCM were looking to get them made 18 months ago and still waiting a sucessful one ) so it will have a Bosch 044 pump and swirl pump under the bonnet, using the std pump in the tank as a lift pump to feed the swirl pot.

The turbo hot side has been Zircotec coated, and the headers have been wrapped and heat painted.


The heads were CNC machined by CNCheads in Stockport, also knows as Ric Woods Motorsport.

Engine mostly built awaiting fitting of manifold.



One of the concerns I had was the injectors.
Despite being (supposedly) new ECUTek 800 c/min injectors, fitted by Litchfields, they may have been a problem with the mapping issues I had suffered. So I insisted they were cleaned and flow tested.
Surprise surprise, they came up short - 2 injectors consistently failed to flow the full volume of evenly.

So a set of Deatschwerks 1000 cc/min were ordered. Parallel fuel rail feeds to be sorted at same time. This will all go nicely with the swirl pot / Bosch 044 fuel pump. Wonder if it gets a fuel pressure reg / gauge too ... have to ask!

Engine was back in the car around the 8th, will be fired up next week!








Bit tight that CAIK and FMIC pipe .. need to fabricate a new seal for inner wing as the AEM CAIK one no longer fits

12/2/13

Engine fired up and sounds great ( so I am told .. it's 300 miles away !!! )

Only little niggle is the drive by wire throttle stepper motor seems to be sticking, that's being sorted right now!


The engine building garage's Owner, Alan Jeffrey, is running the engine for 50 miles ( on a very low boost, rev limited map ), change oil, run in for 500, change oil, run in to 1000 miles, change oil to semi synthetic, then map properly. Full race rom, dual fuels etc with auto blip on down shift, launch control, flat foot shifting ( but not speeddensity ), in gear boost control, etc. As I had before.
Nice.

Expect to go get car in a week or so, most likely end of next week.


Happy happy joy joy!

Been told today that it drives very smooth, it's had 50 miles ( to from Alan Jeffreys country house ) and oil change, and will get the next 500 on over the next couple of days.

Won't be long ........ I hope!

Over 500 miles on the new engine, another ( mineral) oil change.

Might well be available for collection / mapping Friday / Saturday. After another oil change to semi synth at 1000 miles.










Bit tight on that CAIK and the FMIC pipe.... otherwise fine!

Initial rolling road run while mapping, 1.4 bar, apparently plenty more to come!




At 1.54 bar was 482 bhp and spools 400 rpm earlier on road and a couple of 0.XX bars higher!

Getting back Saturday, need to learn to drive again!!!!

No meths map, garage prefers I get a better ecu to go meth and / or go higher on the motor ... Syvecs anyone going spare??

Ohh yeah, I initially told them I was disappointed with that output and low boost ( usually set for 1.6, 1.7 bar + ) , but got put in my place as it as work in progress!

Not sure if I upset Alan J when I said I was disappointed with output - not made what turbo was rated for even though pretty well every other SC turbo exceeds the rating, AND I had posh head work, RCM headers, cold air induction kit, 1000 cc injectors, FMIC etc.

I did expect a bit more than the base 460 bhp and more torque.

He said it was an early run, 1.4 bar during mapping.

It went to 1.54 bar, which from air consumed around 482 bhp, but no graphs.


It's not a problem, drives very well, very quick in the gears, IS faster than before even if the torque is not much more, and nice and smooth.
Got a safe engine to press on with!


And seems around 2-24 MPG !!!

All very impressive stuff. Looks great as well

Thanks Mick, missing yours yet?

Thought it had just a head gasket leak ( was heads lifting / passing the head gaskets ) but something funny was found and when stripped it was the usual ring land failure, cylinder 4.


Gave me the excuse to go for the full monty though!

If I am really honest then no I am not missing the Scoob. Enjoyed many years with the Impreza models and have met some nice people who are now good friends. Quite disillusioned with Subaru these days and I just couldn't buy another

Collecting my new Peugeot 508 GT next week so a complete change of direction now

Still get a buzz out of projects like yours, interesting and nice to see enthusiasts searching for that perfect car. Well done mate and thanks for posting it up

Thanks loads Mick, glad others are interested .. I enjoyed other peoples build threads so thought I should do my own too!

Hope you enjoy the Pug, you may have heard Subaru are not bringing the Impreza to the UK in future, so maybe your boycot campaign worked or they realised they mucked up!