Enforced Project

[SpecB]

Been a while since I've updated this or really done anything to the car but I've been having symptoms of early stage HG failure for a while now, well basically since Germany. This coupled with a couple of fuel cut type issues have prompted the final admission that the engine has to come out to be looked at.

Plan is to take the engine out myself over the next couple of months then get it off to Alyn as ASPerformance. Hopefully the HG has not caused any other issues (engine runs fine, no white smoke and oil is ok, just bubbling in the header tank and lots of coolant pushed into expansion tank if any boost is used). I'll get a few other jobs done on the car while the block is out being checked but I hope to have it rebuilt with CDB insert s and further uprated head studs along with Cosworth HG's so it can take a bit more boost.

[BIG"E"]

Good luck with things Nick

[555_Si]

I have a hoist if you need one.

[SpecB]

Originally Posted by Wagon_Si

I have a hoist if you need one.

I may take you up on that, thanks! I'm going to do a lot of tidying up of hoses and wiring at the same time, probably going to bin the A/C as well as it isn't quite right at the moment with the high pressure side pipes getting exceptionally hot.

[C. J.]

Would of thought the cost would be the same to go 2.35 as having the block done .
By the time you sell current block and pistons keep the rest and add the money for closing it's not going to be far off ?
Yes the closing seems to work but there is a reason poeple use the 2.35 out of choice for a track car . Your choice but just worth thinking about before you spend you money
And don't forget even on a refresh you may end up buying new pistons if it's more than a minimal hone

[SpecB]

I'm going to get it looked at once apart before making any decisions and as you say may just go for a 2.35 or even a CDB 2.1 if it looks the best option.

Having the block closed is around £500 and if I don't need much else that will be the route I take otherwise I'll be in the market for a CBD either 2.2 or 2.0. What crank and rods do you use for the 2.1 or 2.35, I obviously have forged 2.5 rods and a 2.5 crank

[C. J.]

As above use the same length hence saying sell block any pistons and you have everything else for a 2.35 or 2.1

[SpecB]

I'll need to check if the heads have been re-chambered for a 2.5 I guess as if they have I'll need to replace them with std ones as I guess the 2.1 and 2.35 have smaller diameter chambers?

[C. J.]

Their be fine you use a 2.5 head gasket

[SpecB]

Good call, that makes sense! Have to weigh up the costs of a CDB insert vs buying a block and getting the thrust conversion done (factoring in selling my block).

[C. J.]

Can sort machining out if needed

[SpecB]

Once I've got the block out and had a look I'll be in touch - what's the going rate for 2.2 blocks these days, I know I can get a 2.0 for around £350-400.

[C. J.]

Put a 1 in front if it !
£1250 up , can sort one of those too

[SpecB]

Well the cars moved for the first time since 2013! Turned it over a few times to prime the oil and she fired up first time!

Only moved it 20m though to get her out of the garage so I could tidy it before putting her back. Hopefully I should be getting the engine out over the holidays then it's decision time, could still be another one breaking for parts but hopefully not.

[C. J.]

Could always buy my 2.35 & turbo

[Steve_PPP]

Hope you don't end up breaking it mate

[SpecB]

Originally Posted by C. J.

Could always buy my 2.35 & turbo

Even though it's a very good price it's a bit beyond my needs or plans!

If I do rebuild I'm looking at a smaller turbo and faster spool, possibly a MD321T or SC46 but on a closed deck 2.5.

It all depends on the state of the engine when I take the heads off, hopefully the bores etc. are all 100% then I can reuse all the main components.

Current thinking if all is well is to get Alyn to do a closed deck insert then rebuild with new seals and bearings, Cosworth stopper HG and the Cosworth high tension 11mm head studs. Adding a head refresh and possible light port & polish if funds allow. I'd downsize the turbo as mentioned above to give a high torque fast spooling road car still around the 450 mark.

If the engine is fubar I'll probably go the 2.1 route on a CDB or break it.

[Bolesroor]

Originally Posted by BlueBugEye

Been a while since I've updated this or really done anything to the car but I've been having symptoms of early stage HG failure for a while now, well basically since Germany. This coupled with a couple of fuel cut type issues have prompted the final admission that the engine has to come out to be looked at.

Plan is to take the engine out myself over the next couple of months then get it off to Alyn as ASPerformance. Hopefully the HG has not caused any other issues (engine runs fine, no white smoke and oil is ok, just bubbling in the header tank and lots of coolant pushed into expansion tank if any boost is used). I'll get a few other jobs done on the car while the block is out being checked but I hope to have it rebuilt with CDB insert s and further uprated head studs along with Cosworth HG's so it can take a bit more boost.

My wagon stayed at Carnetix today with the same HG symptoms
Like you Nick remaining optimistic on possible `other` damage.

Engine coming out to check,then machining etc if diagnosis is correct?

H and I had an eventful return trip courtesy of BR via Melton Morbray,Leicester,St Pancras then home.

Cost of that for 2 singles was £123.80 and the Goverment want us to use public transport more!

[Lucky]

Originally Posted by Bolesroor

My wagon stayed at Carnetix today with the same HG symptoms
Like you Nick remaining optimistic on possible `other` damage.

Engine coming out to check,then machining etc if diagnosis is correct?

H and I had an eventful return trip courtesy of BR via Melton Morbray,Leicester,St Pancras then home.

Cost of that for 2 singles was £123.80 and the Goverment want us to use public transport more!

. Thats gutting mate. PM'd you anyway.

[SpecB]

How much of an issue was yours showing, mines only been pushing coolant into the expansion tank, no overflow yet even on the ring, but I did get some very odd behaviour when crushing on light throttle then accelerating the car cut then restarted with a nice loud bang!

Hopefully the engine should be out in the next three weeks - pics to follow.

[Bolesroor]

Originally Posted by BlueBugEye

How much of an issue was yours showing, mines only been pushing coolant into the expansion tank, no overflow yet even on the ring, but I did get some very odd behaviour when crushing on light throttle then accelerating the car cut then restarted with a nice loud bang!

Hopefully the engine should be out in the next three weeks - pics to follow.

Coolant in the expansion tank, overflowing causing loss of coolant?Temperature issues when stationary especially after boost but only picked up on longer runs as to and from work gauge showing normal, was topping up weekly,thought it was a leak or similar, no unusual noises or general peformance issues.

Main problem this year is I haven`t used the car very much due to family issues although its been bothering me a lot and I have been keen to get it looked at. Finally today ran up to Carnetix in Melton Morbray for them to check,service mot etc,no traffic issues so straight there bar a quick stop at Peterborough services, car ran sweet at legal speed limits with the odd quirt now and then only when I pulled up at the garage temperature gauge is creeping up rapidly, fans running etc mega bubbling in the expansion tank. Will have confirmation when engine pulled out and will post findings.

[Bytes]

Originally Posted by Bolesroor

My wagon stayed at Carnetix today with the same HG symptoms
Like you Nick remaining optimistic on possible `other` damage.

Hope all goes well with this Steve

[Bolesroor]

Originally Posted by Bytes

Hope all goes well with this Steve

Thanks Alan.

Apologies to Nick on hijacking his thread.I`ll start a new one once I hear about the outcome

[SpecB]

Hopefully we'll both get away with it! Much as I like the smoothness of the H6 in the Legacy I do miss the rush of the impreza.

[SpecB]

It's out!

[Ginola]

holly engines batman

[Steve_PPP]

Been busy then mate!

Hope it goes back together easily once the engine is sorted

[Hongkongfooi]

Paul finch your man for rebuild imho

[SpecB]

Heads are now off - bores look perfect and HG showed traces of a leak between cylinder 3 and the water jacket, no water in the bores so as I hoped only a minor combustion leak under boost. Plan now as funds are tight is to replace the head gaskets with Cosworth items, refresh the heads slightly as they're in pieces anyway and do a large amount of tidying up of the wiring/pipe work as the engine goes back in.
Probably going to reduce the size/capacity of the turbo to give a solid but fast spooling 400.

[seventune]

How's she coming alone?

[SpecB]

The engines made it to the floor! Hopefully off to the engine builder next week, then ready to refit.

[Hongkongfooi]

Originally Posted by BlueBugEye

The engines made it to the floor! Hopefully off to the engine builder next week, then ready to refit.

Who is doing the build?

[SpecB]

It's going back to Williams Motorsport for full head rebuild and skim plus the block re-decked then reassembly with Cosworth Gaskets and belt. The weak link in the original spec was the Cometic gaskets!

[SpecB]

Engine was collected today.......



Off to be refreshed inc, using new bearings and Cosworth HG along with full head rebuild

[ScoobyStu]

Glad it's coming along mate, be good to see it and you back in the game....so to speak

[scotty]

Originally Posted by BlueBugEye

Engine was collected today.......



Off to be refreshed inc, using new bearings and Cosworth HG along with full head rebuild

I do like a bit of DIY that's a good way of transporting your engine under cover out of the weathers harm hope you get the engine back all fixed soon .

[SpecB]

Engine has been split now, beatings were perfect as are the bores gudgeon pins were slightly worn and need to come from Germany so won't get the engine back this week!

All ready for a light skim, decks refaced and cosworth gaskets and baffle plate.

[BIG"E"]

Originally Posted by BlueBugEye

Engine has been split now, beatings were perfect as are the bores gudgeon pins were slightly worn and need to come from Germany so won't get the engine back this week!

All ready for a light skim, decks refaced and cosworth gaskets and baffle plate.

Good news then, glad your beatings are good..

I would not have thought you are into S&M

[SpecB]

Bloody autocorrect!

[seventune]

Not too bad all in all then.

[SpecB]

Probably could have got away with just the HG's but better safe than sorry.

[scotty]

Good to hear that the bug will be healthy again and back on the road soon unless you are doing some more mods to it .

[SpecB]

Just planning a tidy up when the engine goes back on, would like a turbo swap if the right one comes up?

[scotty]

Originally Posted by BlueBugEye

Just planning a tidy up when the engine goes back on, would like a turbo swap if the right one comes up?

If I hear or see of a sc42 or something like that going for sale or swap up here I will let you know .

[SpecB]

First delivery of new parts arrived yesterday!

[scotty]

Originally Posted by BlueBugEye

First delivery of new parts arrived yesterday!

If I knew you were ordering gaskets I've got gaskets sitting in the house brand new for headers, turbo to down pipe and bolt kit and two bolt up pipe gasket to headers .

[SpecB]

That's a bugger! It was slightly annoying having to buy 4 inlet manifold gaskets to use with the thermal spacer!

[SpecB]

Here we go!

[scotty]

Yep think the baffle plate and cossie gaskets will do the job very well liking it .

[SpecB]

It's back! Well at my parents as I couldn't be in all day waiting for the delivery! Should have it in the garage by tomorrow evening then I can start re-assembly!

[BIG"E"]

Originally Posted by BlueBugEye

It's back! Well at my parents as I couldn't be in all day waiting for the delivery! Should have it in the garage by tomorrow evening then I can start re-assembly!

[Ginola]

Excellent!

[ScoobyStu]

Good to hear mate, nice one.

[seventune]

Hazzarrrrr!

Awesome stuff dude. Bet your itching to get on with it arn't you?

[SpecB]

Engine is back now to start re-assembly with a few improvements to various hose routes etc.



Full spec of the engine now includes:
Engine
Std EJ257 Block
Nitrided Sti 9 Crank
ACL Main & Big end bearings
Williams Motorsport Forged Rods
Wossner Pistons
Sti 8 AVCS Heads
ARP 11mm Head Studs
Cosworth 1.5mm stopper head Gaskets
MD321x Turbo
Spec C Inlet Manifold
Phenolic Spacers
Silicone inlet hose
Grimmspeed AOS
Throttle body coolant bypass
Pennine Subaru billet fuel rails with fuel labs adjustable FPR
Blue injectors reflowed to 650cc
Wallbro 225 Fuel Pump in tank
Williams custom modified High Pressure Oil pump
Milltek 3' Exhaust (sports Cat)
Hybrid FMIC
K & N Large cone intake
Setrab Oil cooler with Mocal thermostatic take off.
Competition Clutch 4 paddle clutch and lightened flywheel.

[scotty]

Nice engine spec list would love to see what that will be pushing once its all plumed in and running .

[seventune]

Coming together nicely dude. Look forward to seeing how she goes

[SpecB]

Engine is now fundamentally complete, ready to go in and be fired up!

[Hongkongfooi]

You ever try the stage 4 cc clutch before nick?

[scottpolestar]

Wow spec list on that engine going to be a quick car

[SpecB]

I went straight for the stage 5 purely for stock reasons! The 4 probably would have done and driven better I imagine.

[Lucky]

Be good to see it back on the road. Looking good mate.

[BIG"E"]

Originally Posted by Lucky

Be good to see it back on the road. Looking good mate.

[SpecB]

Finally got it back in - we'd put the engine mounts on the wrong way round so took the whole engine out again - only took and hour to get it all back in once they were swapped over!

Engine needs bolting in fully and then it's the re-plumbing!

Quick question on the first start with syvecs is it best to disconnect the crank or cam sensor?

[SpecB]

Will post a pic when it's daylight bit it's all in and ready to go, just the fluids to do tomorrow then turn the key!

[Bolesroor]

Originally Posted by BlueBugEye

Will post a pic when it's daylight bit it's all in and ready to go, just the fluids to do tomorrow then turn the key!

Nice one Nick,
hope you as pleased as I was when I got mine going again

[SpecB]

It's alive! Well it was after I connected the 'other' wire to the starter motor!

Driven it out of the garage and down the private road at the back. Just need to sort insurance and MOT then put around 400 miles in to bed the bearings then it's time to drive it again!

[Steve_PPP]

Good to see its back mate, look forward to seeing it sometime soon

[SpecB]

Just dropped it in for the MOT, fingers crossed!

[seventune]

Awesome stuff. Nothing quite like getting a scoob back on the road

[SpecB]

Not feeling 100% confident it'll pass though felt a bit of a misfire as I drove to the MOT (about 500m) thinks it needs a bit more of a run before it'll be happy but here's hoping!

[SpecB]

Been a while now but have got the car through the MOT even with a massive misfire! Which I now think I've traced to a failed coil pack- well none of the others are this shape!



Hopefully Dad's Forester has the same coil packs so we'll use one to check if that's definately the issue before ordering a new one.

[C. J.]

Have some here

[SpecB]

If dads are not the same I may take you up on that to test of it is definately the coil pack that's gone, I'll probably replace the whole set with new if it's definately failed.

[SpecB]

Running on 4! Time to try and rack up the miles now!

[Steve_PPP]

Nice one mate Be good to see it back on the road

[BIG"E"]

Originally Posted by BlueBugEye

Running on 4! Time to try and rack up the miles now!

[SpecB]

Just starting to get things moving along again....

[Rdlangy1]

Oooooh shiny!!

[Ginola]

Cheer get her out and about Nick

[SpecB]

What are you saying Dave, I did a whole 1000 miles in it last year!

I need to get the headlight sorted as the passenger ballast has gone and it could do with a Map check but Duncan is proving hard to get hold of at the moment so I may look at other options.

[555_Si]

will pop down to garage at weekend and look for ballast

[SpecB]

No Problems Si
I need to find out where to put the new catch-can so it's accessible for emptying and then find the time to do a few decent runs in the car to find out where the map issues are - I also need some new brake disks as mine are starting to wear on the inner face.

Plus it appears I also have minor rear diff and engine oil leaks!

[SpecB]

At least now it's all tucked up safe rather than on the drive!

[SpecB]

Cheers to Si for the ballast and Wanda for the delivery service! Now I need to get out to the car tomorrow and see if it'll fit!

[SpecB]

Once again Subaru have scuppered my plans by using more than one design of Ballast on the bugeye!

Fortunately with a tidy up re-wire and copious amounts of contact cleaner I appear to have got the old one working!

And I've got the catch can fitted all be it on a temporary bracket although I have a plan for final fitment.
[/URL]

[Rdlangy1]

Looks sweet

[Hongkongfooi]

Originally Posted by BlueBugEye

Once again Subaru have scuppered my plans by using more than one design of Ballast on the bugeye!

Fortunately with a tidy up re-wire and copious amounts of contact cleaner I appear to have got the old one working!

And I've got the catch can fitted all be it on a temporary bracket although I have a plan for final fitment.
[/URL]

needs a good clean Nick!

[SpecB]

You haven't seen The outside Tim! I'm not sure if I've actually cleaned it since Germany (2013)!

The inlet manifold etc. Is all coming off at Easter from a proper clean and tidy up with some wiring and hose routing improvements.

[SpecB]

Just got booked in for June 3rd with Duncan @ SRR - hopefully we can sort out the Knock issue at high revs out and possibly turn up the boost a little.

[SpecB]

Had a run with Duncan and Charlie having helped push Jimmy (Of Alfa vs Lucky Fame) into his trailer in a £2.5 Million Bizzarrini which was having the carbs rejetted.



Slightly down on power from 2013 due to an aged turbo (it was on Charlie's legacy once!), reduced compression ratio due to thicker HG on the rebuild (Cosworth 1.5 vs Cometic 1.2) and a limit of 1.6 Bar due to the std MAP sensor. But Duncan has given it a bit more low down (around 10BHP) to compensate for the loss at the top end and also pulled a bit at the top to stop the occasional knock warning I was getting when flat out in 4th or 5th.

[Hongkongfooi]

not bad at all then....improved driveabilty?

[SpecB]

Nothing significant - there wasn't much of a change Duncan could make to the map it wasn't that far out which was good given it was a rebuilt engine!

The boost & power comes in so early anyway to have further reduced lag or put more power in earlier would probably make it less drivable!

[Scott.T]

Nice smooth power and a spot on fuel plot, nice and safe at the top......bet that drives well.

[SpecB]

Does feel very nice to drive - I may be forced to change the clutch to something more user friendly as the car is likely to be needed as a commuting car more often now and it's a it embarrassing bunny hopping into work or having to launch it at traffic lights to make sure it goes!

[Rdlangy1]

Glad ur happy with the results Nick - looks great