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Old Fri 28th October 2016, 07:26 PM
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EZ30D Conversion 1st gen Liberty - The RS6

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)
http://www.ausubaru.com/forum/archiv...p/t-25423.html
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'.

[UPDATE: 13/11/2016]

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.

[UPDATE: 21/11/2016]

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.
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Last edited by Donkeytits1; Sun 12th March 2017 at 09:50 PM.
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Old Fri 28th October 2016, 09:18 PM
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Awesome work so far DT!

Sweet looking Gen1 you've got there. The H6 with a manual should make it get up and move when you want it to

I'm looking forward to reading more about your build

Cheers

Bennie
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Old Fri 28th October 2016, 09:52 PM
pitrack_1 pitrack_1 is offline
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Seriously impressive stuff, especially the interfacing.

Just hope something silly like an leaky old head gasket doesn't trip you up... but that's trivial for someone of your skills.

If I had 1/10th your skills I'd be 10x better than I am.

Wish you the best of luck and look forward to progress.
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Old Mon 31st October 2016, 07:18 PM
legacytt legacytt is offline
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H6

Very Impressive. I did a manual conversion in a Gen 3 Outback years ago and the constant check engine light was a pain. Is a great engine though and i had it hooked up to the same gearbox setup as yours.
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Old Mon 31st October 2016, 10:42 PM
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Cheers for the encouragement guys! The electronics manufacture is coming along sweet, I drilled the board this evening, I'll tin it and finish it off tomorrow and I'll post a couple of pictures.

Legacytt: Did the VDC enjoy being disconnected from the transmission computer? It would have been complaing with its own warning light if it was. This is the only hurdle I can foresee with an Outback manual conversion using this method of emulating the TCU.

Was talking to my housemate this evening, I think an Outback manual conversion is definitely going to happen aswell. My housemate has a bomb of a gen 3 with a headgasket problem, smooth manual box and matching wood grain interior trim. What better thing to do with a car that with a car thats going to the tip. Do a conversion, design a kit, sell it on
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Last edited by Donkeytits1; Sun 12th March 2017 at 09:51 PM.
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Old Thu 3rd November 2016, 07:28 PM
legacytt legacytt is offline
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Outback

Mine didn't have VDC but I understand from others that it has issues when the auto is removed.
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Old Sun 13th November 2016, 10:42 PM
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Old Mon 21st November 2016, 01:07 PM
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Old Mon 21st November 2016, 06:13 PM
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Quote:
Originally Posted by Donkeytits1 View Post
Interface board is built up.
You designed and etched this board yourself? That is a thing of beauty! Mind if I ask what technique/technology you used to design and etch those tiny intricate tracks?
And here I was thinking I did well to make a tacho for my car with a 555 timer and a piece of vero-board

That loom looks a nightmare, you just couldn't do this sort of thing without the right wiring diagrams. Best of luck with this project, I'll be looking forward to see how it turns out!
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Old Mon 21st November 2016, 07:24 PM
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Sounds like the 2001 is the base model with the 2003 a revision model with the added pump controller.

Cheers

Bennie

Ps: you'll only be able to update the first post to a maximum of 5000 characters or 8 images iirc
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