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Old 10-11-2007, 10:36 AM   #1
IllNastyImpreza
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Default My slow ass build continues

OK so after more than A YEAR ....I have finaly gotten my engine back from the machine shop... The real work starts

Brand new Cobb block

phase 2 ej25, fully closed deck, darton sleeves, fully balanced and blueprinted to 10,000rpm. oversized Clevite bearings, cobb pistons(JE) and rods. Cometic HG, ARP headstuds. STI oil pump(not shimmed) and pan.
98 DOHC heads, decently ported , mildly polished. 3 angle valve job. STOCK INTERNALS




2005 Legacy GT 5MT




Pulling the busted up stock tranny...

What a mess....

Note to self..... drain tranny before removal

cracking transmission case for Speedometer gear removal...



just a busted up core....only need the speedo gear anyway...


Tomoro: pick up completly rebuilt 05 Legacy GT 5MT..... anyone know how to install these damn speedo gears ?

More pics to come !
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Old 10-11-2007, 10:36 AM   #2
IllNastyImpreza
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ok So I got it


still seperating...

pulled the 4 bolts

the shift fork assembly...

case apart ! ...check out first gear

there she is....the speedo gear !

its made out of plastic ???


now to throw her back together.... then I'm off to pick up my new LGT tranny !
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Old 10-11-2007, 10:37 AM   #3
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well I spent today organizing the garage...and setting out parts to get started tomoro.

I started bagging up bolts and screws, so I can head to the bolt and screw place. I'm going to replace all my hardware that has seen better days

I ordered all the trasmission parts I need to installing the speedo gear, and the axels.

I also have decided that I am going to break in the engine the first 1000 miles with NO turbo. This will alsmo make my install alot easier at first !

started cleaning up the engine bay.....tomor I will steamclean &or preasure wash

took the last of the casting marks off the intake manifold....tomoro I finish polishing and reassemble

so far it looks like everything will bolt right back onto my phase 1 heads on phase 2 block


After much antagonizing, and quetioning about WHY my car is not done yet... I have summoned up the motivation to get that bitch on the road !


To day me and some friends got back to work !

Split the 05 LGT case to speedo gear install...



Gear installed...





cleaning up the edges for real-sealing... I bought a new gasket for the tail end but didnt end up using it...we just siliconed the crap out of the thing


my budy the dodge tech gettin his hands dirty on the Scooby... he loves these things , "they're TIT to work on" he says


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Old 10-11-2007, 10:37 AM   #4
IllNastyImpreza
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ok so I thought just puting in another boring old tranny would be....well....boring

so I painted my LGT 5mt blue... the pictures don't do it justice...it really does match the car much better in person.



Goin up !



Thats me...



o yeah baby..



there she is...



all in...for the most part...



My favorite towel/fender cover

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Old 10-11-2007, 10:38 AM   #5
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re-installing the intake manifold...



BUT first... the Grimspeed phenolic spacers...



these things are THICK!


check out the port job...



they barely fit on the gasket stud...





and finaly, the manifold installed... most everything included with it

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Old 10-11-2007, 10:38 AM   #6
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ok so I realized I have some "open holes" in my engine !
This is a phase 2 ej25 block with phase 1 DOHC heads...









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Old 10-11-2007, 10:39 AM   #7
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Pics from Tonight...


Ripped out both knuckles...



Fight to the death to get the ****in ball joints out... it kicked and screemed for 20 minutes....but we finaly won



Clutch reinstalled...



Had to take out the EGR tube and lengthen it....all due to the THICK ass manifold spacers



butterflies



Both balljoints out...



started playing with my new oil cooler...



Can someone please tell me how the hell to attach this thing ???



Since the car is a 98, and BOTH ball joints where original (only 45k miles though) they where in there GOOD! We ended up hairline fracturing both knuckles while spreading the jaw open... luckily its not structural, the part the cracked it VERRY thin and just used to keep dirt and crap out. once they are re-installed I'm gona clean it up and weld her up nice anyway.

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Old 10-11-2007, 10:40 AM   #8
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UPDATE:

Got the engine back in...just to realize that the bellhousing bolts from my 98 where too short ...and there was only 1/2 as many as I needed !










Right now its just chillin inthe engine bay...Haning there....waiting for me to pickup the Hardware @ the dealer tonight
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Old 10-12-2007, 02:42 AM   #9
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Quote:
Originally Posted by IllNastyImpreza View Post
re-installing the intake manifold...



BUT first... the Grimspeed phenolic spacers...



these things are THICK!


check out the port job...



they barely fit on the gasket stud...





and finaly, the manifold installed... most everything included with it


now thats an awesome combo...that intake manifold with the 8mm phenolic spacers!!!

Justin
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Old 10-12-2007, 06:16 AM   #10
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Good work! Looks like things are coming along nicely, and some great photos amongst the dodgy ones... ; )

Couple of questions, why dya have to change the speedo drive? Surely a newly built 5MT would have one fitted...? Also, is that all you did to first gear? I've seen 'boxes that have had 1st, 2nd AND 3rd stripped to the core!!

You might want to install your spark plugs and coils before dropping the motor in - pain in the ass to do it after...

And with that oil cooler, looks like the take-off plate is fitted in place of the oil filter with the bit thats threaded at the top - the bottom should be a hole with a thread to screw on through the take-off plate, where your filter normally would. Get a remote filter assembly from Summit Racing, about $50, and run one of your hoses from the centre of the take-off, to the remote filter assembly you mounted out on the inner fender somewhere, then run another hose to your cooler, then back to the outer port on the take-off plate on the block. You may need some extra hose and fittings/adaptors but Summit will have all that... Good Luck!!
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Old 10-12-2007, 09:03 AM   #11
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Originally Posted by Legacy_H6TT View Post
Good work! Looks like things are coming along nicely, and some great photos amongst the dodgy ones... ; )

Couple of questions, why dya have to change the speedo drive? Surely a newly built 5MT would have one fitted...? Also, is that all you did to first gear? I've seen 'boxes that have had 1st, 2nd AND 3rd stripped to the core!!

You might want to install your spark plugs and coils before dropping the motor in - pain in the ass to do it after...
Actualy yeah I did throw em in there...I just didn't get a chance to snap some shots.

Quote:
Originally Posted by Legacy_H6TT View Post
And with that oil cooler, looks like the take-off plate is fitted in place of the oil filter with the bit thats threaded at the top - the bottom should be a hole with a thread to screw on through the take-off plate, where your filter normally would. Get a remote filter assembly from Summit Racing, about $50, and run one of your hoses from the centre of the take-off, to the remote filter assembly you mounted out on the inner fender somewhere, then run another hose to your cooler, then back to the outer port on the take-off plate on the block. You may need some extra hose and fittings/adaptors but Summit will have all that... Good Luck!!

ok cool thanks, I'll check out summit.
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Old 10-12-2007, 12:15 PM   #12
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OK I picked up the 05 LGT bellhousing bolts... 5 out of 6 work great... I sapposed I have to pick up one from a phase 2 ej25 for the one that doesn't fit...

I got the engine in...



BUT ... the sti motor mounts DON"T FIT !!






By comparison, the sti mounts have more of an offset on the bolt pattern... which means they are JUST BARELY too wide to fit in the "notch" on my crossmember... DOH !

I'm thinking I could modify my crossmember...but I would rather not.
I'm just going to throw the old mounts back in for now.

anyone run into this ??
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Old 10-12-2007, 02:02 PM   #13
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ok I hooked up a couple wratchet straps, pried and pried...wacked it with a hammer, and finaly she plopped into place





the engine is "IN" !

Now...to hook everything back up .............
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Old 10-12-2007, 05:33 PM   #14
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hot ****!
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Old 10-12-2007, 08:19 PM   #15
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Awesome ride.
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Old 10-25-2007, 01:07 PM   #16
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UPDATE:

ok the engine is in...
you might have seen my other thread on why I'm getting a CEL after 3 minutes of PERFECT idle...

well Wit2003 swung by my house last night with his handy dandy code reader. And it turns out its a freakin Idle Air control code ! DOH

I cleaned her out last night...but to of no avail. It ran an extra 1.5 minutes @ idle, and then threw the code again !

I'm going to swap it out with the IAC from my 98 legacy...and hope it runs !

pitures when I return !
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Old 10-25-2007, 09:49 PM   #17
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ok so here she is...



I cleaned the CRAP out of my IAC again today... as well as basicly any other sensor or whatnot with a hose going to it....

lets hope she runs tomoro !



can someone tell me what sensor this is ?(located underneath pass. side intake manifold) ( I broke off the crappy plastic nub...basicly all of it.... it was basicly shredded by the time I got the rest out of the hose )... yes this was the ONLY thing I have broken so far ! *knock on wood ! *



it would normaly go underneath the manifold here on the passenger side...

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Old 10-26-2007, 12:14 PM   #18
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ok so I fixed it !

the IAC works...

the car is still idling rather high...1800rpm

but SMOOTH, and no CEL !

I think I will clean her out a little more once I get some miles on the car.

I got both axle seals in. Hooked up the axles, and hammered the pins in.
I had to use the old pins cuz the 05 LGT pins where too thick (should have got 98 RS pins )

Both knuckles are on, I just gota throw the rotors and calipers back on...then tighten up the top hats on the suspension towers.... I think it definatly got rotated...and I have no idea which of the 3 bolts goes where anyone??

ALSO... how the FREAK do you tighten up the tie rod end nuts ... the tie rod ends themselves keep spinning !!
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Old 10-26-2007, 02:06 PM   #19
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I got the Tie rod ends in.... the bad news is the old cotterpins(whats left of them) are basicly siezed inside the old tierod end.... I just spun the nut on as tight as I thought appropriate. I was going to weld a bead on there just to make sure its not going anywhere.... But I think I'll get an alignment first. Won't they need to take out the rod end and spin the rod for my alignment ??

Also.... good to know about the IAC...freakin adjustable ! awesome
now...to figure out which way it down
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Old 11-02-2007, 12:28 PM   #20
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update:

car is together ....and running !

I would say it 80% done
I spent yesterday working on the finishing touches, finding missing bolts, straightening up wiring, and working on the interior. I just have to install my CDT es 4 way, and DCX-730, re-hook up my subs, cd and dvd player, and she will be pretty much done (for now)





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Old 11-02-2007, 01:24 PM   #21
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That little thing you broke is the solenoid for the fuel tank suck setup. Triggers at certain points breathing the fuel tabnk. It's not really needed but you will throw a CEL if it's not connected. Mine connected to nothing other than the wires and stashed under the manifold
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Old 11-03-2007, 03:05 PM   #22
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nice car and setup, but wtfseats???
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Old 11-04-2007, 04:39 PM   #23
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nice car and setup, but wtfseats???
whats with all the hAtErS ! ?

They actualy came with the car, Full red leather seats(front and rear) door cards, rear pannels and everything...

I actualy picked up some new black leather front and rears, but I havn't gotten around to throwing em in yet.
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Old 11-04-2007, 06:12 PM   #24
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did you not notice the HUGE lip left from the gasket being much larger than the actual intake port?
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Old 11-04-2007, 08:30 PM   #25
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Quote:
Originally Posted by GrimmSpeed View Post
now thats an awesome combo...that intake manifold with the 8mm phenolic spacers!!!

Justin
Thank goodness you quoted 7 pictures to say that!

Quote:
Originally Posted by Homemade WRX View Post
did you not notice the HUGE lip left from the gasket being much larger than the actual intake port?
My ported heads (Cobb stage 1) are the same way. I certainly don't know as much about head porting as you do, but my thinking is that adding a bunch of intake port volume by opening the port all the way out to the gasket could actually be detrimental. Of course, I'm N/A, so (I think) maintaining intake velocity is more important in my case.
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