My Engine rebuild

[Tyler]

My big ends were on my way out so i have decided to take my engine out and try and rebuild it myself... As the engine is out i am going to turn it into a little project. Just got the Inlet manifold back from being powder coated red.

Photo's so far..

[Tyler]

On order.

Looking forward to following this one.

[Tyler]

Originally Posted by Crowman

Looking forward to following this one.

Cheers mate, i'm looking forward to have my car back in working order

[C. J.]

Good to see someone else home brewing

[Tyler]

Originally Posted by C. J.

Good to see someone else home brewing

Thanks CJ....

[Chunk]

Looking good mate

Will be keeping an eye on this thead, looks a goodun

[Tyler]

Originally Posted by Chunk

Looking good mate

Will be keeping an eye on this thead, looks a goodun

Cheers Chunk, this is the first time i have done anything this serious so lets say that i am taking my time....

[Chunk]

At least you are having a go. Loads of people on this site who can lend a hand

Originally Posted by C. J.

Good to see someone else home brewing

Good luck with the build and many thanks for posting on SES

Never get tired of threads like this

[Tyler]

Originally Posted by Chunk

At least you are having a go. Loads of people on this site who can lend a hand

True, plus it is a hell of a lot cheaper.... :thumb:

[Tyler]

Originally Posted by MrX???

Good luck with the build and many thanks for posting on SES

Never get tired of threads like this

Thanks MR X..... Should have the heads off weekend, depending on how it goes......

[Tyler]

Instead of gaining on power i seem to have lost quite a few horses. I have done it all backwards, from 240hp i seem to only be on 1mp

[stiggy]

I see you got it on here before I did....

[Tyler]

Originally Posted by stiggy

I see you got it on here before I did....

Had to Stiggy.... i don't want no surprises now...

Can't wait to see the end product of this.

I wish I had the knowledge to do this kind of thing, hats off to you mate

[Tyler]

Originally Posted by worzel

Can't wait to see the end product of this.

I wish I had the knowledge to do this kind of thing, hats off to you mate

Cheers worzel, i can not wait to drive my car again.....

This is all new to me i have only ever done this sort of thing on mopeds, i have basic knowledge but this is all new to me!!! Fingers crossed though...

[666subaru]

Originally Posted by Tyler T 299

Cheers worzel, i can not wait to drive my car again.....

This is all new to me i have only ever done this sort of thing on mopeds, i have basic knowledge but this is all new to me!!! Fingers crossed though...

Full respect then sir, I would like to do more on mine but I just have not got the equipment and time to do it, what are the piston pack you have pics of and where did you get them from please buddy, and whats the benifit? sorry about the many questions, but doing my homework for later this year

[Tyler]

Originally Posted by 666subaru

Full respect then sir, I would like to do more on mine but I just have not got the equipment and time to do it, what are the piston pack you have pics of and where did you get them from please buddy, and whats the benifit? sorry about the many questions, but doing my homework for later this year

Cheer's matey..... The piston pack is off ebay and the Pistons are CP Forged pistons, the conrods are Manley conrods (lol), from what i know (which is not alot by the way) the forged pistons are stronger then the originals i think they are solid compared to the originals and the metal's used are stronger, i think the set comes with top end bearings, locking clips, piston rings and ARP2000 bolts for the conrods, i still got to get the Big end bearings which i am having a little problem finding....

The pistons and conrods i have ordered have been tested upto 700bhp according to the company, obviously that is with the supporting mods, also once out i have a tool to Glaze bust the bores, which i have been advised to do. I will post up Pics as i do most of this anyway so it makes sense... I hope this makes sense to you and is correct, i am sure if i am wrong some kind person will set me straight.....

[AndyWRX]

looks good so far mate, keep up the good work, look forward to updates

[Tyler]

Cheers Andy.

[Spooky]

Tyler, random question...

Where did you get that uber tent from!? i want one very much so!

[C. J.]

Originally Posted by Tyler T 299

Cheer's matey..... The piston pack is off ebay and the Pistons are CP Forged pistons, the conrods are Manley conrods (lol), from what i know (which is not alot by the way) the forged pistons are stronger then the originals i think they are solid compared to the originals and the metal's used are stronger, i think the set comes with top end bearings, locking clips, piston rings and ARP2000 bolts for the conrods, i still got to get the Big end bearings which i am having a little problem finding....

The pistons and conrods i have ordered have been tested upto 700bhp according to the company, obviously that is with the supporting mods, also once out i have a tool to Glaze bust the bores, which i have been advised to do. I will post up Pics as i do most of this anyway so it makes sense... I hope this makes sense to you and is correct, i am sure if i am wrong some kind person will set me straight.....

If you need and machineing done Steve at Roland L. Alsop otherwise known as SMG is your man and will also sort you out with any gaskets , seals ,bearings & cosworth parts you could ever need . Used him for mine and very happy with the prices .To deglaze/ hone block & resurface heads and block £95 +vat
Their in Chobham Tel 01276 858073

[Tyler]

Originally Posted by C. J.

If you need and machineing done Steve at Roland L. Alsop otherwise known as SMG is your man and will also sort you out with any gaskets , seals ,bearings & cosworth parts you could ever need . Used him for mine and very happy with the prices .To deglaze/ hone block & resurface heads and block £95 +vat
Their in Chobham Tel 01276 858073

You read my mind CJ that was going to be my next question, i am going to Glaze bust the bores myself, but like i said i was having problems finding decent gaskets and big end bearings. Do they do high performance bearings and gaskets?

[Tyler]

Originally Posted by Spooky

Tyler, random question...

Where did you get that uber tent from!? i want one very much so!

Spooky there is a place on the A22 in Godstone, it is the main road to eastborne, it is a big camping shop loads of tents outside... This one is a 5 birth tent, set my old man back around £400, but that was a while ago.. I think now they go for around £250-£300...

Hope this helps.

[C. J.]

Originally Posted by Tyler T 299

You read my mind CJ that was going to be my next question, i am going to Glaze bust the bores myself, but like i said i was having problems finding decent gaskets and big end bearings. Do they do high performance bearings and gaskets?

Yep i got the following from them

ACL 11mm stud kit
ACL race bearing trust & end
Mahle low silicon forged pistons
1.5mm cosworth head gaskets
Cosworth kevlar cambelt
Cosworth cambelt guide
Cosworth baffle plate
All seals for bottom end build

[Tyler]

Originally Posted by C. J.

Yep i got the following from them

ACL 11mm stud kit
ACL race bearing trust & end
Mahle low silicon forged pistons
1.5mm cosworth head gaskets
Cosworth kevlar cambelt
Cosworth cambelt guide
Cosworth baffle plate
All seals for bottom end build

Cheers CJ, i should be calling him on the weekend....

[C. J.]

sooner the better as there is normally 6 to 12 week wait !

[Tyler]

Will do, cheers matey..

[Tyler]

Latest update, it has been a slow process, just waiting for the parts to come now, have only got one piston out so far, just need to get one more out, so i can hopefully split the block easier..... Fingers crossed....

What parts are you waiting for?


Keep up the good work, both on the engine and posting up your progress

[Tyler]

I have on order CP Forged pistons, Manley H beam conrods, stage 2 bc cams, titainium valve springs and retainers, ACL race bearing kit, ARP 2000 head studs, and a performance head gasket kit.

Cheers for the support though.... It is needed because sometimes it gets depressing seeing the engine like that..

[AndyWRX]

sounds good mate are you changing the turbo too?

[scatz]

You're a braver man than me pal and kudos to you for it

I've always figured the best way for me to have a nicely uprated engine is to buy a spare and work on it rather than oink my current one out....that way, if I really fubar'ed it I'd still have a car

Keep those updates and pics coming

[willis]

all this excitement is getting me thinking as i have a spare jdm v3 sti lump in my garden it has top end damage could be the start of operation wagon me thinks

[SUBARMAN]

Originally Posted by willis

all this excitement is getting me thinking as i have a spare jdm v3 sti lump in my garden it has top end damage could be the start of operation wagon me thinks:sm:

hurrah!!

[Tyler]

Andy i will be getting a bigger turbo when i get a new job and save up for it...

Scatz if i had the money that would of been my exact action, i am only doing it myself as money is tight, but to be fair i am enjoying it and i am looking forward to putting the new toys in......

Willis if you have the funds and space to do it, go for it, it starts of daunting, but once you have boxes to put parts in and a tyre pen to label parts nut's and bolts it is not to bad.... Go for it!!!!!!

[Chunk]

Sounding good mate

Keeping an eye on this thread, looks interesting

[Tyler]

Cheers Chunk...

Finally got the block split yesterday night, have not been working on the car that much as have been fixing other cars (not through choice) There was a hidden 12 sided bolt hiding behind the remainding ac bracket. Latest pic so far.

[Tyler]

It's christmas again, my presents have arrived.......

[stiggy]

Look good mate NOW stop dribbling and get to work on it, you have meetings to attend

[C. J.]

Will it be in for the weekend !

Very nice matey.

[Tyler]

Stiggy believe me i want this done asap...

C.J i would love to have it all in for the weekend but i need a crank as mine is no good, i have spoken to Stew and i am waiting for my mate to get back to me as well, plus i need to pay for my ecu from Simon, also need to get the shims.. Hope to be done within 2 weeks dependant on if there are any more issues... Is there a meet this weekend?

Cheers Worzel..

[Tyler]

Haven't been able to do much to the engine as i have been preping my bike for the Isle of Man run, but Yesterday i managed to fit the conrods and acl big end bearings as well as the main bearings, crank conrods and seal the block back together. I have also fitted the titainium valve springs and alliminium retainers. Just need to sort the shimes out. I would of had the piston's in today but the cer clips for the wrist pins were to big. So i need to get them tuesday.

[Tyler]

I have lapped in the valves, fitted the valve stem oil seals, titainium valve springs and alliminium retainers. I also have torqued the cam caps ready for measuring the shimes.

[Tyler]

It has been a slow process with a few problems on the way but i managed to get the engine in, by myself, i had problems with the engine crane. Managed to sort it out and fitted it in myself... Lets say that there was a few horrible words said in the process but i managed to get it all in. It is all bolted up now pretty much, just need to buy some turbo bolts which i have managed to loose and a turbo oil feed banjo bolt. I am also having a problem putting that release bearing hydrolic thingy majig ontop of the gearbox.... Not good..

Cracking job mate

[Spooky]

Nice one T! Imagine you're going to be nervous when you first turn the key!?

Well done mate.

[C. J.]

well done , have some banjo bolts and exhust bolts if not sorted

[Tyler]

Cheers Guy's..........

I am not going to lie to you Spooks, i am bricking it.... Its really wiered because in some ways i can not wait to turn the key and in other ways i am not looking forward to it if anything goes wrong....

[midlife2]

Good luck mate, just rebuilt mine and started her up last night, know how you are feeling.

[Tyler]

Originally Posted by C. J.

well done , have some banjo bolts and exhust bolts if not sorted

Cheers C.J, i might have to give you a call if i get stuck....

Good luck mate, just rebuilt mine and started her up last night, know how you are feeling.

Cheers mate, was that your first engine rebuild???

[midlife2]

On a scoob, cheated a bit though as i had the bottom end built by Enginetuner

[Tyler]

Engine is in and is not turning over, i am hoping that it is just a sticky starter motor. Also need to find out where all of the boost/vacume pipes go as that has confused me, does any one have any diagrams that i can follow??

[Tyler]

I managed to start the car!!!!!!!, the problem was that the power was damaged on the starter so i took it apart and managed to tighten the bolt that sticks out of the starter.... I carried on turning it over with the ht leads out to build up the oil pressure, then stopped and plugged the ht leads back in and he started first time.... The only problem was he was reving high, i am just hoping that it was just because the boost pipes are prob in the wrong places and the intercooler pipe that leads to the throttle body is not on. I only ran the engine for about 4-5 seconds, but the main thing at this stage is he started.... Think its time for a well deserved beer.... Lets just hope it runs proper once i iron out the creases....

[stiggy]

Well done mate should be proud of yourself, look forward to seeing you back in it.

[2-jaffacake-tone]

nice one mate could be the ICV stuck or a pipe off.

[Skullfudge]

You are a lot braver than me mate.

If I would have put it back together I would have got someone else to start it incase it blew up


Good stuff & well done.

[C. J.]

Good that ity started , note for next time pull the crank sensor plug off when building the oil pressure up its then one plug not 4 to pull off and plug back in . as jaffas said pipes & ICV are a good place to start

Mate, I'm really happy for you that it's all turned out ok.

You have done a cracking job and you should be proud of of what you have acheived

[Tyler]

Cheers guy's....

Tone is the ICV on top of the inletmanifold? with the settings ABC???
Also where does the pipe go from the top of the throttle body?? I might need to give you a shout at some point when you are free...

Cheers Clive that was one of the most heart stopping moments of my life....

Thanks for that C.J, lets just hope that i dont need to rebuild another one, but i have taken note.. lol

Thanks Worzel, i couldn't of done it without some of the advise that was given on the forums, so a BIG thanks to those who gave me advise when i needed it.....

[2-jaffacake-tone]

give me a ring if you get stuck

[Tyler]

Cheers Tone, i will prob end up giving you a shout a little later after work...

[Tyler]

Little bit of bad news, the car seemed to be running fine, the engine was wining though a little bit but i am hoping that this is just because the piston rings need to bed in (can someone confirm this) There was no blue smoke at the back and the car idle'd beautifually... My mate noticed that there was a big puddle underneath the car of oil, i have not had a look at it since as i was to upset and felt like crying so i left it alone over the weekend, but i think i know what the issue is. On the top of the block at the front there are inspection points, well atleast that is what they look like, on each half of the block, they are allen key bolts and are about the size of a 50 pence piece. I took them off them to replace the copper washers and when i tightend one of them i managed to over tighten it and it snapped off the block. I tried to mend it myself with some chemical metal which i don't think has done the job, i know for a fact that everything else is tight and sealed as i took my sweet time putting it all back together. Just seeing if i can get a call out welder to see if they can repair it..... I really do hope that it can be fixed as the car seemed to be fine...

[midlife2]

Sorry to hear the news mate. Maybe worth checking the auxillary belts, also i would drain the oil to check just in case.

[Tyler]

Cheers mate.

Ding ding round 2, engine taken out for the second time, secound hand block from Stew... Cheers mate. Engine out and all parts onto new block in a day. Just need to bolt on the heads. Decided to tidy up the engine wiring loom as well. Lets just hope i don't break anything this time....

[Tyler]

Car is up and running now and is on road finally..... oooooo how i missed driving the scoob... Car seems to be running beautiful, a little knocking noise but that is the exhaust bracket.... Look forward to seeing you all at the next meet...

[stiggy]

Great job, looking forward to seeing you there now it's up and running. Enjoy the

[Tyler]

Originally Posted by stiggy

Great job, looking forward to seeing you there now it's up and running. Enjoy the

Cheers Stiggy..... It has been a while.. lol

Mate, I'm really glad it's back up and running well.

You have done a cracking job

[Tyler]

Thanks Worzel, i can not wait now till it is run in and i get my Simtek ecu...

[Skullfudge]

Tyler, I just had the pleasure of a visit from one of your work associates Mr Stiggy.

He mentioned that you would love to jump in my passenger seat one day. Maybe you could jump in at Japbash?

[Tyler]

Originally Posted by Skullfudge

Tyler, I just had the pleasure of a visit from one of your work associates Mr Stiggy.

He mentioned that you would love to just in my passenger seat one day. Maybe you could jump in at Japbash?

Now that sounds like a Damn good idea to me clive , just worried that after i do that i will never be happy with my car ... Also you might have to physically pull me out of you're car too.

[Tyler]

Couple more goodies brought for the old boy..

Can't beat a bit of bling matey

[Tyler]

After getting the car mapped a little while ago i had a issue where the engine was burning a lot of oil from the home made build...... So another engine was purchased. I found out why the car was burning oil, it was the CHEAP!!! (flee bay) valve stem oil seals.... It is my fault for being tight....

Any way i drove to west Yorkshire to pick up my lovely new lump. It is a Forged P1 engine, with wisco forged piston's, Eagle conrods, arp head studs, acl race bearings, 440cc injectors, and for £50 a full manifold wrapped, 6 paddel clutch with lightend flywheel and STI4 heads.

I took my old engine out on a Monday and buy Tuesday it was back in and running, but i had a really bad waterleak and it got all into where the clutch was, so the clutch worked for a little bit then started to slip... (to be fair i hated the clutch any way as it is a daily used car) So then i had to find the water leak... JOY... It took some time to find the leak and ended up taking the Inlet manifold off to only find that it was a loose sensor !!!

Now all i had to do is drop the gearbox and changed back to the standard clutch.... That took we about 2 days also but was a struggle.... I HATE ANYTHING TO DO WITH SUBARU GEARBOX's.......

Well after that i took the car to Simon as the car nearly passed its MOT on emissions when i have no cats at all, so a trip to see Simon was needed.

Got on the rollers and Simon done a blinding Job as usual and the car made 318bhp 330... So i am pleased. Still more to come...

[Tyler]

I thought i would start re-conditioning my brakes that i have had sitting in my bedroom for about 3 months... Not greatly pleased but it is kind of better then before...

[Tyler]

Have not updated this for an extremly long time and a lot has gone on since.. Think when there was a problem with the site i lost some of my updates...

Fabricated a custom numberplate brackets..

One of the brackets i fabricated...

Fitted to fog light cover...

Fitted to car..

Number plate and grill fitted, and old number plate cut off...


Picked up some version 7 STI seats.






Well after not that long fitting the Subaru 4 pots, i decided that i needed a lot more stopping power so i brought myself a set of these...




...

Yep you guessed it.. A genuine P1 splitter



Brakes are fitted as well as my prodrive wheels..



Wheels were sent off to be sprayed.




After my gearbox loosing the will to live i replaced for a JDM 5 speed



Where's the Wally LOL?????????????????



turbo in, with the braided turbo line..
Braided turbo line

Vf28 beside a TD05 18g
..


The rear diff ready and waiting to go in, just waiting on new seals to come so i can replace them.
Rear anti roll bar is partly in, just have to either source a a new bracket or attempt to drill out the broken bolt.
I also have some new gauges waiting to replace my old cheap gauges..
Prosport Stepper gauges...

Also brought a DIY flocking kit and i am going to attempt to flock all the chavy blue bits in my car... That should be fun :confused2:

Originally Posted by Tyler 1

Centre pod holder flocked..

Few goodies

[/QUOTE]

Fitted 550cc injectors and Walbro 255, put rear seats back in as wanted to make sure the walbro primed before it did so..
Fitted the rear drive shafts now, the driver side one clicks into place without a circlip.... Feels the same as the left side as it clicks into place.. So fingers crossed on that..
Also fitted a Sti steering wheel and fitted the exhaust... So coming along.. Also ordered a brand new radiator and the water feed pipes for the Turbo.
Even had a little time to add a little fine detail to the wheels, i know nobody likes the blue lip on the wheel but i wanted to be a little different..


Brand new Radiator turned up today which i paid £43.50 for, delievered!!!
And also my £170 order from Opie oils!!!


Fitted all the white pipes which are now black fitted the turbo water pipe, Rad with both rad fans, also fitted all the wiring for the 3 new Prosport gauges, made sure that i hid as much of the wiring as possible, with the help of my dad... All wires were soldered and heat shrunk.. Fitted white boost pipes as well. The turbo down pipe is in place just needs to be secured.
All that is left is to fit the actual dials in the pods, fill gearbox and diff up, fill engine and anti freeze and fit the intercooler pipes then ready to start the old boy, fingers crossed!!!
Little pic of the engine bay in progress..


Prosport gauges fitted and home made flocked bits also fitted..

Little video below..

[Tyler]

Sent the Car off to JGM for mapping, He made 351.1bhp which i was very happy with, Simon was not able to road map it as it had no MOT or Tax at the time so i got that done and guess what happened a day after??? Yep i broke my gearbox, second gear syncro went.. Slave cylinder went and causing me to break the second gear syncro, so managed to get my misses to drop me to Dans the next day and got a slave cylinder off him.. But now with this issue of not having a second gear there was no point me going to see Simon for the road map, so waited till another five speed come up. Then after i had got it my misses decided to surprise me with a complete 6 speed setup, including R180 diff shafts and rear brembo setup.. VERY happy bunny
Managed to fit it all last Sunday but noticed i had a few issues, my downpipe was hitting the gearbox craddle and i had a water leak So went to see Dan and John and they sorted it all out with just mne turning up out of the blue, which i really appreciated. So that was all sorted, managed to sort out my passenger window issue also which turned out to just be a bent Pin on the switch.
So now all that was needed was the fine tune by Simon, so went down there yesterday and he has worked his magic and sorted the Kangarooing and set the launch control for me... Which i am over the moon about..
Power is really nice but want more now that i have the 6 speed box looking for a MD321T, also went to Canada Coach works to get a estimate on my front bumper and then all i need is to get rid of the front lights and either go for Morettes or Crystal.. So all coming together now...

The present from my lovely misses..

Present unwrapped

Mates who come round to watch lol

Old box beside the new

Drive chain completly out


Rear hubs removed


Me and my mate dealing with the final bits


nearly sold the car a couple of weeks ago as didnt know if i could afford to keep it as was moving in with my new misses. But she did not let me sell up and offered to sell her own to help us, but we decided in the end to keep both and now i have started tuning her 2.5 Focus st Turbo... Well i suppose i should say Volvo...
Well i have now sourced a MD321S Billet which is in my bedroom..


Also brought some Harnesses and a Harness Bar which is on its way.. No they are not my seats... Wish they was though


Have also brought a set of STI pedals..

Just need a turbo inlet pipe and possibily exhaust manifold, but to be fair i dont think i will as funds are a bit on the low side.
Also have a set of Crystal headlights that i will be picking up at some point when i actually have a chance too.

[Tyler]

Also removed black paint from rear Brembo calipers..

[Tyler]

Well going to have to sort out the turbo a lot sooner than I expected as think my tdo5 18g has lost the will to live.. screams like a supercharger.. so just need to source a 76mm turbo pipe..
here are the goodies I have waiting to go on so far

[Tyler]

Fitted crystal lights .. car looks sooooooo much better I feel. Really happy with them.



before

Spacer fitted..

After

[Tyler]

Little bit more done. Manifold fitted and 3" exhaust fitted..
Just about fitted in the company car.......





Now car has been washed and waxed and under the cover waiting for some bits from RCM and all new couplers for intercooler.


really hope the end is near.. feels like im fighting a loosing battle.

[Tyler]

More goodies

[Tyler]

Engine apart at the moment to fit the Turbo inlet pipe. Might give the engine a little clean..

[Tyler]

Managed to get turbo inlet pipe in which was not fun with standard fuel rails and lines still attached.. Painted top pipe black as well, just going to send injectors off to be customised to 900cc and flow matched at lateral performance.

[Steve_PPP]

Blimey, you've been busy!

[Tyler]

Yeah just a little, it was all over a period of time though... Just need injectors, and the lateral performance exhaust manifold and up pipe. then off to get mapped hopefully...

[Tyler]

Yesterday I picked up a lateral performance headers and a rcm up pipe, just need some welding done to the collector as there is a minor hole.





..

Today I managed to get a little done, but as it was raining not much.. My neighbour saw me standing in the rain with a umbrella and offered me this..


Got the inlet manifold in with the new gaskets, also Managed to clean the block a little as well as taking out a few bolts and copper grease them up.



.


800cc injectors should be purchased this week, then just need to get exhaust mani on as well as turbo, and customise the gearbox cradle as it's hitting my 3" down pipe.. So slowly getting there..

[jonnyricer5]

Looking super smart.crystals look so much better!where did you get the hub spacers from
andhow much??cheers

[Tyler]

Cheers jonny... Mine are eibach, but cdf racing also do a set.

http://www.larkspeed.com/index.pl?c=...ARU&s=category

[stiggy]

Looking good and getting there mate...

[Tyler]

Cheers Pete, long time no speak mate..

[Tyler]

Got a little bored whilst waiting for my injectors and timing belt guide...

[bang.]

is difficult to remove the gearbox from a reduced height?
without using the lift.

[Tyler]

Originally Posted by bang.

is difficult to remove the gearbox from a reduced height?
without using the lift.

Its not the easiest of things to do, but as i have done it a few times now you learn, and you learn quick..

Easiest way i have found so far is to use a trolly jack to bring it down and jack it up in place.. But either way it is a lot easier on a ramp, as the first time i did it was at my mates work place.

[Tyler]

These turned up today..

My 800cc injectors

[Tyler]

Got a few bits done today, power steering pump alternator in ac in and injectors are in. Run into 2 issues,

1 can not remember which injector cable goes to which injector on the drivers side, as my bits of tape came off

2 the injector connector doesn't fit think I need a top slot connectors

Think I need a phase 2 connector or something... Joy...