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!