So just a quick post to kick off my build journal
So I'm about a third of the way through an EZ30D converion.
I have the car
And I have the donor car.
The donor car is a stat write off i got for an OK price, and the recipient car already has ESP suspension, a 5 speed with 1:1:59 lo range, DCCD and 0.78:1 5th gear and its soon to have an R180 torsen rear end. So it'll be a good package for driving all day with a bit of off road and a skid or two.
So far I have the engine running in the donor car with the ECU on its own, as it will be in the conversion. This means:
- Compiled a full wiring diagram (from 11 pages of EZ manual) and documented all changes
- VDC disconnected
- TCU disconnected
- 3 speed radiator fan output converted to single on/off signal
- A/C setup to accept A/C on and self shutoff signals only
- Emulated fuel level
- Unnessesary signals like 'Clearnace light' removed
- Taco re sampled to run on 4cyl taco
- No 'Check Engine' lights
A number of threads have said this cannot be done (here's a nice summary)
and it's taken some time. Basically I have pulled this off by emulating the TCU diagnosis 'I'm in 'Drive' and I'm OK' signal with a small 8 pin micro controller and a bunch of voltage divider and pull up resistors. The micro controller also takes care of resampling the taco signal so I don't have to go around changing dashes.
I say I'm about a third of the way through because I haven't actually touched the mechanical side of things at all yet. I hear that part is quite simple, but who knows what problems I'll face.
The plan going forward is to make this a complete plug and play affair. I intend to pull the loom out of the Outback and strip it of everything except for what is needed in the conversion. I have a plug from an EJ22 ECU that I will attach to a custom made circuit board that I etched this evening. This will contain all the electronics. I then intend to run the new loom in parallel with the old loom and simply plug it in to where the old ECU used to go and into one plug in the engine bay (to carry the power for the extra O2 sensors). Only other things to be swapped is the EZ fuel pump (different pressure and ran with a separate fuel pump controller, which would need more emulating) and the immobalizer (PITA or imposible to remove, good security to have)
I think all this will lead to an interesting experiment - I am hoping to be able to link the batterys and earth the engines together, run two or three extra wires and run the EZ, from the EJ car, while the EZ still mounted in the donor car. Should be able to simply un plug the silver car and drive it somwhere at any time while I sort problems out. Point of this will be to validate the wiring and the board before I start tacking the mechanical side of the swap - The Silver car is still my daily and the more things I can have right before it's off the road, the lower my stress levels will be during the conversion! Especially as work is busy at the moment. Whether or not I pull this particular little experiment off will depend on whether the loom is long enough.
So thats about it for now. I'm pretty invested in this, and its going well so far. Will keep you all posted, and hopfully put up some resources that will help out other people with future EZ30D swaps. The TCU emulator should work with manual conversions for the outback. Would need to see how the VDC computer handles being disconnected from the TCU. I didn't test that. All I know is currently the ECU is happy but the rest of the dash is lit up like a christmas tree. VDC and the TCU certainly are not happy about being severed from the ECU. I think I'm half planning on converting a EZ30D outback after I'm done with this project.
Just a quick note:
Reason I went for EZ30D rather than the 'R':
- Cheaper - Allot cheaper. Old outbacks seem to be written off after a scratch at the moment
- Shorter - No AVCS things sticking out the front. less complications with radiator clearance
- Cable throttle - Don't have to change pedal box, and the old Cruise control should be compatable. Cable cams are the same, it's amazing what Subaru resuses.
- No CAN bus - Whilst that means actually less cabling, you need an EE degree to interface to it. Thats why everyone goes stand alone with 'R' swaps.
- Its still powerfull - You only loose 20kW out of around 180 for the 'R'.
Removed the bulkhead harness from the donor car today. Mission. Requires dash out, heater core diconnected and removed, pretty much everything behind the firewall needs to be removed.
Interface board is built up.
Next stage is to unwrap the loom and eliminate all the unnessesary cores. Then it will hopfully be slim enough and long enough to run allongside the existing loom in the gen 1.
Loom is stripped down. Had to cut the connectors from the upper part of the loom as the middle section quickly became a tangled mess. Rejoined the diagnostic connectors, and am chasing the 10 or so stray wires I have left.
Interesting note, the 2001 model does not appear to have the fuel pump controller which is present in the 2003 service manual. This will simplify the wiring overall, as I should be able to leave the original gen 1 fuel pump wiring alone. But it is causing headaches now as I don't have an accurate wiring diagram, and I need to review my wiring plan to work out what exactly what I need to connect to ensure the fuel system behaves in the way it is intended to. Which I'll need to achieve through inspecting looms that are already pulled apart. And I can't test anything, as the car is obviously not wired up. Oh well, got all afternoon.