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Old 04-23-2012, 10:38 AM   #1
visualsinz
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Member#: 160900
Join Date: Oct 2007
Chapter/Region: South East
Vehicle:
2004 WRX STI
JBP

Default 04 Forester XT M/T Build

I traveled 2 hrs about 2 weeks ago to pick this 2004 Forester XT up from a Ford dealership.

I drove it home and noticed a little bit of smoke (white, oil smell). I threw on my full TurboXS turboback exhaust and at that point realized something was wrong as the smoke was just pouring out. The car ran fine though.

I swapped turbos (4 times), but this was not the problem.

I came to the conclusion that it was either a bad head gasket or a bad piston and decided to do a small engine build.

Lessons I have learned... Always get a turbo car compression checked.

Background:
I have owned 5 turbo Subaru in the past 6 years and 1 non turbo.
2002 WRX- Stage 2
2004 STI- Stage xxx- 375 awhp
2006 WRX- Stage 2
2002 WRX- Stage 2
1998 2.5RS
2004 Forester XT

So back to the Forester build.
These are the parts I have bought so far:
New EJ257 longblock
Gates timing/ water pump kit
ARP head stud kit
Full OEM gasket kit
Killer B oil pickup
STI TMIC
V9 VF37 full twin scroll setup
TurboXS turboback exhaust
BC valves, springs, retainers
BC stage 3 heads
AP fuel rail/line kit
18x8 Rota Tarmac
2007 WRX shocks/springs

I'm sure there is more.

I am taking the heads tomorrow so they can start on the cleaning/machine work.
The Forester

Empty

Engine pulled

The breakdown starts


Continued


Heads off

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Old 04-23-2012, 10:38 AM   #2
visualsinz
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Member#: 160900
Join Date: Oct 2007
Chapter/Region: South East
Vehicle:
2004 WRX STI
JBP

Default

New Block



Valves, springs, retainers... hopefully the cams are waiting in the mail


Cams came in- BC stage 3

Painting before and after


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Old 04-23-2012, 10:38 AM   #3
visualsinz
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Join Date: Oct 2007
Chapter/Region: South East
Vehicle:
2004 WRX STI
JBP

Default

New 08+ STI Oil Pump Installed

Gates Water Pump Kit Installed


Heads back: BC stage 3 cams, valves, springs, retainers. Port and polished and 2 angle valve job. ARP head studs and OEM STI head gasket.





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Old 04-23-2012, 10:38 AM   #4
visualsinz
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JBP

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Took a break. Back on it.







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Old 04-23-2012, 10:39 AM   #5
visualsinz
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JBP

Default

More parts added, most notably the JDM intake risers are cleaned, painted, and installed and the AP fuel rails are mocked up.




More added, plus fit the IM to decide how I will be running my fuel lines.






Last edited by visualsinz; 04-25-2012 at 02:40 PM.
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Old 04-23-2012, 10:39 AM   #6
visualsinz
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2004 WRX STI
JBP

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More work. I'm going to have to take the IM back off and hone out the 2 center bolt holes. I'm also going to put some teflon paste in the rail connections while I'm at it.





More parts finally arrived and installed.
STI IM came in. I modified it, and it fit great.
Killer B oil pan came in also. fits like a glove.



Last edited by visualsinz; 05-08-2012 at 01:43 PM.
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Old 04-23-2012, 10:42 AM   #7
visualsinz
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JBP

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Finally started working on the car again.



Last edited by visualsinz; 06-26-2012 at 09:36 AM.
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Old 04-23-2012, 10:43 AM   #8
visualsinz
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JBP

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reserved 7
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Old 04-23-2012, 10:43 AM   #9
visualsinz
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reserved 8
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Old 04-23-2012, 10:43 AM   #10
visualsinz
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reserved 9
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Old 04-23-2012, 10:43 AM   #11
visualsinz
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reserved 10
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Old 04-23-2012, 10:03 PM   #12
Abest10
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Location: Ohio
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04 FXT

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O my. That is and is going to be a one hawt Forester. Ive been looking at buying one. How do you like yours so far?
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Old 04-24-2012, 08:39 AM   #13
visualsinz
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JBP

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I love it, granted it needs some improvement in the handling department.
There's not much to say about a Subaru that can be faster than a STI with a STI turbo swap, STI TMIC, and a tune and still haul and pull a ton of stuff.
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Old 04-24-2012, 09:44 AM   #14
Slurpyy08wrx
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Got a lot of courage buying a new car then ripping the engine out and building it! I wish I had the courage to do it to my 08 wrx, I do have another DD.. Hmm haha.

Good job so far!
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Old 04-24-2012, 08:59 PM   #15
Abest10
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Well I will be watching this build thread closely. I have a STi intercooler already just need the forester to put it on haha. keep up the good work!!
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Old 04-25-2012, 09:15 AM   #16
visualsinz
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JBP

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Thanks. I will have more pics up today for the work I did last night.
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Old 04-25-2012, 02:40 PM   #17
visualsinz
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updated
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Old 05-03-2012, 11:41 AM   #18
visualsinz
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JBP

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My Forester oil pan (whick is the same as the 2.0 wrx) will not work with my Killer B pickup, so I ordered a Killer B oil pan.

I am also waiting on my 04 STI intake manifold. The JDM TGV deletes I bought gave me some problems. The 2 center mounts are slightly different, so I went to notch my stock manifold (at 11 at night) and ended up notching the wrong side.
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Old 05-08-2012, 01:43 PM   #19
visualsinz
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updated
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Old 05-08-2012, 08:39 PM   #20
LiCelsior
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PSM

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damn thats a nice build.
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Old 05-10-2012, 02:35 PM   #21
rifxt
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Aspen White

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What ended up being the problem? Head gasket, piston, or something else?
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Old 05-12-2012, 11:18 AM   #22
visualsinz
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JBP

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I think head gasket and maybe a ring. I didn't investigate further once I got the new block.
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Old 05-16-2012, 04:34 PM   #23
visualsinz
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JBP

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Well, probably won't be updating for a couple of weeks after these. I've spent about $8k on the build and the cash flow has run out. I still have to buy another downpipe and clutch and take the car to Altanta to put on the dyno for breakin/tune.
Mod list to date:
New EJ257
Complete head rework including port and polish
BC stage 3 cams
bc valves, springs, retainers
All new oem Subaru full gasket kit
Gates timing belt, pulley, and water pump kit
11mm 2011+ STI oil pump
AP fuel rail and line kit
DW 850cc injectors
Killer B oil pan, baffle, and pickup
STI intake manifold
JDM intake risers (TGVless)
STI TMIC
FMS silicone intercooler/bpv piping kit
Perrin V2 inlet tube
GS AOS kit
3 Port BCS
FMS catless uppipe
Deadbolt SZ55
TurboXS RFL catback exhaust
GFB dual port BPV
07 WRX suspension
Rota Tarmac II 18x8
Cobb AP V2
S.S. braided AVCS/turbo lines
Everything is new except for the turbo and IM. Looking back, I wish I would have bought more used, but it's so hard on a build like this. Being new, I should not have to worry about defects or wear.
I will be setting the timing and buttoning it up, but other than that I am stuck for a bit.



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Old 06-26-2012, 09:36 AM   #24
visualsinz
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Vehicle:
2004 WRX STI
JBP

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Finally started working on the car again.


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Old 06-28-2012, 09:16 AM   #25
visualsinz
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JBP

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New development: TRading the Deadbolt SUperzilla55 for a SZ65 (60lb/min wheel), 3" AP inlet, and Externally gated uppipe.
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