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Old 11-04-2010, 06:12 PM   #1
340Duster
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Member#: 52314
Join Date: Jan 2004
Chapter/Region: South East
Location: Following the green weenie
Vehicle:
2002 PSM WRX 16G-XT
'13 500 Abarth

Default The latest my EJ20 died now I'm rebuilding it thread full of semi-usefull information

Forward
Since someone asked if I was working on a write up of my build, and so Juan can have a thread to read I figured I will write a mini-saga of events.

Preface
My stock internal EJ20 died at 105k miles. All injectors checked out however. This was all on a ported TD04. I had already planned on building an engine to safely run in the 320~hp range on the side. This just made me start a bit early.

Let's Begin
In trying to combine the most budget minded build and reliability here's a list of what I decided to go with. I will also try and include costs of everything including labor and shipping.

Required
Short block and heads - $400
OEM Crank - $330
0 Mile STI rods - $150
Mahle .5mm Powerpak pistons/pins/rings - $450
ACL HX Race bearings - $110
11mm Oil pump - $120
OEM Gasket kit - $300
Valve cover gaskets - $20
OEM Oil cooler - $200
Various OEM hoses water/vacuum - approx $100
Group N engine mounts - $130
Replacement ACT clutch disc - $205
Gates timing/water pump kit - $400?
Lifter shims x 13 - $65
Permatex Ultra Gray - $7
Plastigauge - $4

Labor
Bore/ Hone - $100
Balance - $120
Valve job - $100
Pressure test of heads - $70
Clean block/ file rings - $50

For Free
Polishing of rod beams
TGV delete porting
Assembly
Advice on NASIOC

Optional
Witch Hunter injector service - $110
Walbro fuel pump - $80
Step colder plugs - $30
Blouch TD05-16G-XT - $905
Ceramic coating - $75
(soon to be tuned) - $400

Already installed
Catless up pipe and TBE
3 Port EBCS
Ebay TMIC
K&N short ram intake
Mishimoto radiator
ACT light weight flywheel
MRT straight cut 1-4 gearset
Cryo treated transfer gears
STI center and front LSDs

Notes and lessons learned
Make sure you have cleaned every possible spot after you get your parts back from the machine shop. There was metal left over from the honing we had to to clean. Pull all plugs to oil galleries and clean them out with compressed air/ a parts washer.

Use common sense when torquing bolts. I found out the hard way of the misprint in the service manual in regards to the front cam cap bolts

Not sure if anyone else has done this. But we primed the engine on the stand with a 1/2in drill instead of doing it in the car. Just to make sure everything was working before going through all that work. We hooked up a mechanical gauge to the block and spun it over, the drill could make it read 80 PSI, so that seemed good

Right now I'm waiting on the turbo/ inlet to finish it and drop it in the car and then on to the break in/ tuning. Here are all of the pictures I have taken over the course of the project http://www.flickr.com/photos/4913125...7624984952574/, which is taking twice as long as I expected. Anyone feel free to share questions, comments or cuss words
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Last edited by 340Duster; 03-10-2011 at 05:52 PM.
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Old 11-04-2010, 07:17 PM   #2
juanmedina
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07 FPgreen 7.37@95
WRX VF39+E85 12.0, 121mph

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haha great, I hope it all goes well.
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Old 11-04-2010, 11:29 PM   #3
Csquared33
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Join Date: Dec 2008
Chapter/Region: Tri-State
Location: Danbury, CT
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93 2JZ something

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please add some headstuds to that list

**edit just read its already in
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Old 11-05-2010, 08:22 AM   #4
340Duster
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Join Date: Jan 2004
Chapter/Region: South East
Location: Following the green weenie
Vehicle:
2002 PSM WRX 16G-XT
'13 500 Abarth

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Head studs for 320whp?
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Old 02-22-2012, 10:43 AM   #5
millerlite6633
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2002 WRX
Silver

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would you need to have a new clutch and diff for 320 whp?
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Old 02-22-2012, 12:23 PM   #6
KpT KiM
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Quote:
Originally Posted by millerlite6633 View Post
would you need to have a new clutch and diff for 320 whp?
Diff, no. Clutch, probably. Exedy Stage 1 should be good.
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Old 02-22-2012, 01:10 PM   #7
340Duster
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Member#: 52314
Join Date: Jan 2004
Chapter/Region: South East
Location: Following the green weenie
Vehicle:
2002 PSM WRX 16G-XT
'13 500 Abarth

Default

What he said, and it depends on purpose and driving style
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Old 10-17-2012, 08:40 PM   #8
340Duster
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Join Date: Jan 2004
Chapter/Region: South East
Location: Following the green weenie
Vehicle:
2002 PSM WRX 16G-XT
'13 500 Abarth

Default

Bumping my thread here, mainly for Juan I've hit 40k miles on the engine with no issues. Still running strong with hardly any oil consumption. Just goes to show it's not how much you pay to have an engine built, it's in research and attention to detail (and talking to people who are experienced in engine building in general).
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Old 10-17-2012, 09:03 PM   #9
Paul
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00 RSTI Coupe
Twin Scroll 2.5XTR EJ207

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Did you assemble the engine yourself with just plastic gauges and no tq plate?
What kind of power does the car make and what do you do with the car.. Drag/autox/road race/dd/ect
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Old 10-17-2012, 09:09 PM   #10
340Duster
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Chapter/Region: South East
Location: Following the green weenie
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2002 PSM WRX 16G-XT
'13 500 Abarth

Default

Quote:
Originally Posted by Paul View Post
Did you assemble the engine yourself with just plastic gauges and no tq plate?
What kind of power does the car make and what do you do with the car.. Drag/autox/road race/dd/ect
Yep we clearanced the bearings with only plastigauge. It was honed at a shop with no torque plate.

It's a 16G-XT on E85. On 93 it put down 325 on a dyno. It's seen the track just a little bit, and a couple of autoX events. But it's been a DD for the rest of the time in all kinds of SC weather. Plenty of "spirited" driving, meaning it sees full boost and plenty of RPM every day.
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Old 10-17-2012, 11:49 PM   #11
geronimo81
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1996 Turbo Outback
9psi on 91 No EM

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Quote:
Originally Posted by 340Duster View Post

Use common sense when torquing bolts. I found out the hard way of the misprint in the service manual in regards to the front cam cap bolts
I also learned that the hard way. Did you end up breaking the bolt or stripping the threads? I broke a bolt and had to drill it out and have a helicoil put in
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Old 10-18-2012, 12:04 AM   #12
340Duster
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'13 500 Abarth

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Quote:
Originally Posted by geronimo81 View Post
I also learned that the hard way. Did you end up breaking the bolt or stripping the threads? I broke a bolt and had to drill it out and have a helicoil put in
The part of the bolt that wasn't threaded actually stretched and they just didn't torque. So luckily I was able to back them out and just buy new ones.
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Old 12-11-2012, 02:49 PM   #13
RL206
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Great job, I will keep this bookmarked for references!
Holy wow, that piston... haha
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Old 12-11-2012, 09:26 PM   #14
340Duster
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Join Date: Jan 2004
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2002 PSM WRX 16G-XT
'13 500 Abarth

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That's what detonation will do over the period of a week or so
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Old 12-12-2012, 12:39 AM   #15
Cortiti
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haha great, I hope it all goes well.
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Old 12-18-2012, 02:07 PM   #16
verve94
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WRBlue, of course

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tagging to read later.
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