I am thinking about a short block-up rebuild of a EJ20 SOHC for my Brumby (BRAT). The reason for using a EJ20 block is simple - it is within the 10% requirements that avoid an engineering certificate locally (Vic, AUS). So please, no responses of "Go EJ22"... Also, DOHC is out for the same reason (requires cutting the rails, which is an engineering certificate). And ditto turbo.
I am currently running a (phase 1) EJ20J (ex-1998 Forester, early year) in my Brumby, and have read the best (in terms of factory performance) SOHC option is the BL-BP Liberty/Legacy from 2003+, which has a revised intake and heads for better flow. I have been able to obtain a suitable intake and heads for the grand sum of $50, and will have the heads hardness tested and then machined flat (with some mild porting if worthwhile).
I have also obtained a complete long engine (phase 2) EJ202, which will be the basis of my build ($10 due to spun big end bearing). And I have a line on a complete EJ25 (phase 2) with (surprise!) a blown HG.
I have been quoted "around" $600 to machine out the existing EJ20 liners and replace with EJ22 liners. An EJ25 crank will drop straight in (as long as it's the same phase 2 model), and I believe using the stock EJ25 rods will also work - which means only custom pistons (and I would need new pistons for the EJ22 bore anyway).
Externally everything will be EJ20, and as I am using all phase 2 EJ20 block and heads and intake it will all go together (although there is no reason that I know of why I couldn't use the EJ20J block with the EJ202 heads and intake - the only reason I am using the EJ202 block is it minimises downtime and I can then sell the EJ20J as a complete running engine).
The questions I have are,
1. Any obvious issues with the above proposal.
2. Can I use my existing cut-down EJ20J wiring, and adapt it to the EJ202 intake ?
3. As I am using EJ20 SOHC cams, which are not exactly common in the US, would Delta be able to grind them (I am thinking the "1000" grind, which is street version no CELs) ?
4. Will the EJ20 intake be sufficient in terms of flow to support a 2.35L (I know plenty of US guys have fitted EJ20 heads to EJ25's because of the EJ25's HG reputation, but I don't know if they have used a matching intake or have used an EJ22 or kept their original EJ25 intake ?
5. Will the factory ECU handle this, or do I need to go aftermarket (and if so, which brand would be suggested).