Subaru 3.0r Six cylinder with Turbo

Installation details.

 

General:

My goal is to provide all the details you need to install this engine into your aircraft. I started this process 12/6/2005. On that day I received the 2005 EZ 3.0 engine in a crate. Brand new p/n 10100BM500 from the Subaru factory. You can purchase this item for $8k direct from Subaru. Gross weight of that container was 300#.

 

Now, there are some very important… and unexpected...circumstances here. Subaru enthusiast Joel Hall has donated this engine and all of the other components. He arranged this when I expressed interest in developing this engine package. The terms of this deal? So far, it’s just “publish the install details”. Wow! I think I can handle that!

 

 

Engine features:

This Horizontally opposed 6 cylinder engine is rated to produce 220 hp at 6000 rpm. That will jump to around 290 hp with 10” of boost from the turbo. Flight testing will determine my net hp output. Looks like I’ll finally get to use that O2 system for pilot……

 

Unusual items:

· Plastic intake. This is relatively new development. My other engine had a 15 lb cast aluminum intake. This one is only 6 lbs.

 

· Oil pan is cast aluminum. The only steel is the end cap. I’m told this improves rigidity of engine, enhances heat transfer.

 

· No throttle cable. This is a “drive by wire” throttle body. I will replace that with traditional throttle body.

 

· Variable valve timing and variable valve lift.

            http://www.drive.subaru.com/Win05_WhatsInside.htm for more info. It changes the cam timing            and lift depending on rpm.

 

· Independent coils for each spark plug.

 

· Water / oil heat transfer system. Coolant is way more efficient at extracting and releasing heat. This engine takes advantage of that by using coolant system to remove excess oil heat.

Goals:

1)      Put engine details into 3d cad so you can determine mounting and fit to your aircraft.    Completed 1/12/06

2)     Remove unneeded components. Completed 1/14/06

3)    Record and publish install details.

4)    Make any engine mods needed for flight.

5)    Arrive at baseline weight of engine.

I have the engine in 3d wireframe cad. Here is 2d image of where the engine, psru fit the Cozy.

Initial measurements found the intake manifold was too tall to fit my Cozy engine covers. However, the intake is designed to allow you to flip it 180 degrees. I’ve done this. Now the throttle body faces away from the bell housing. I had to saw off one boss on the manifold to make it fit. Some simple plumbing changes needed too.

Before

After tubing changes

Original

Alternator

bracket

Bracket has been

Reduced using

Bandsaw.