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Old 10-13-2012, 01:54 AM   #226
PHATsuby
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Well I came down and it fired right up! So there doesn't appear to be any drain on the battery so I should be good to put it all back together and do the final bit of work. I'm going to spend Saturday doing that and then hopefully take it for a test drive to check everything. The annoying thing is naturally it's going to be raining but oh well...

Ben
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Old 10-14-2012, 03:00 AM   #227
PHATsuby
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Well, I took it out for a drive. Naturally I have multiple issues now to troubleshoot. When accelerating it was cutting out at times, initially I thought maybe I had it in valet mode but that doesn't seem to be the case as it would be somewhat random. My guess is either it's just the fact that I'm low on gas or the filter has precipitates on it from sitting for a while, or the fuel filter is clogged or all of the above.

The more troubling thing is there is coolant on top of the block on the passenger side so I need to track that down, also I feel like after having driven it smells like oil and the whole engine bay is smokey. I would assume there is stuff to burn off but I feel like there could be an oil leak too as I think there could be some drips under the engine. The odd thing is there were literally ZERO drips this entire time it sat and even when I let it idle for extended periods to get to temperature so I need to figure that out too.

I'm hoping it's something easy like a loose coolant hose or something. I'm hoping that when I pull the intercooler tomorrow it isn't full of oil...

time for bed.

Ben
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Old 10-14-2012, 01:13 PM   #228
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I CANT HANDLE THE EMOTIONAL SWINGS IN THIS THREAD.

...in all seriousness, congrats, at least it's moving

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Old 10-14-2012, 03:24 PM   #229
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I can't handle it either! haha

I am still unclear on if the coolant was just sitting on the top of the block originally or not. It's definitely smoking a lot less so hopefully it was just burning things off. The intercooler did have oil in it so that is concerning, I can't tell if maybe I over filled the oil or not.

I will have to monitor that, unfortunately a couple more things I need to do before I can take it up so I'll have to wait till next time for that.

After I filled it up it no longer cut out on the acceleration tests so I hope that is solved but I will test more next time.

A monumental event, the first filling:


Ben
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Old 10-14-2012, 11:16 PM   #230
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Just realized I officially started 8/15/2011, almost 1 year to the day until I filled it up for the first time. Obviously it's not totally done and it's about 9 months over due but either way...so far on a much better track than my H6 project lol.

Ben
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Old 10-16-2012, 12:05 AM   #231
PHATsuby
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It's always fun to get parts haha.



I got my underseat subwoofer today. It is a Sound Ordnance B-8pt, 8" subwoofer, 120w RMS. It has received some good reviews and fits under the subaru seats so I decided to pick it up. I got it from crutchfield, I believe it is their in house brand.

I definitely think bass adds a lot to any type of music and really rounds it out so I hope this helps me achieve full sound and a little thump with a lot less headache than fiberglassing a spare tire well box.

Ben
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Old 10-16-2012, 12:53 AM   #232
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Does the sound ordinance have an internal amp as well? I was thinking about picking one up or maybe one for each seat.

Good to hear it fits under the seat.

Nice to hear you're making progress and resolving some of the issues you had.
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Old 10-16-2012, 06:34 PM   #233
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Yes, it's a powered sub.
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Old 10-17-2012, 01:38 AM   #234
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Figured I'd throw this up for fun. A diff angle from the first fill haha.



Ben
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Old 10-17-2012, 03:36 AM   #235
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I have to say this is a very pleasant read to hear it is on the road and relatively issue free. It's refreshing to read, as I am sure it is for you to finally be driving it. Cngrats man on one heck of a project and a clean BE.

It looks damn good just getting gas.
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Old 10-17-2012, 03:28 PM   #236
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So does this mean your free to come to Nashville and get started on my BE. lol All kidding aside congrats. Can't wait to see some video of it screaming down the road.
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Old 10-19-2012, 11:52 PM   #237
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Quote:
Originally Posted by PDAWG View Post
So does this mean your free to come to Nashville and get started on my BE. lol All kidding aside congrats. Can't wait to see some video of it screaming down the road.
Haha, Unfortunately that is probably not possible but I am willing to help with knowledge/advice if you do ever decide to do a swap feel free to hit me up.

I am planning to do work tomorrow, I have an alignment appointment scheduled for Monday so the plan will be to drive it back if everything checks out...

We'll see.

Ben
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Old 10-21-2012, 10:52 PM   #238
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Well I got the car mostly together and it survived the 90 mile drive back home from Rochester to Minneapolis without incident. No smoking once I pulled into my spot, all spills on the top of the block are evaporated and the coolant temp was totally fine the whole way.

There are some things that concern me though. The misfire issue I thought was solved by filling up is still there. It seems to be mostly an issue when I go WOT instantly vs. rolling into the throttle, or it may be if I go over a certain % throttle I'm not sure. I will have to do some logging and see what is happening. It may be tough to trouble shoot especially if it is mechanical with the fuel pump, maybe the sock is clogged or maybe the fuel filter is clogged, either could be the case like before, or maybe it's something else...

The other concerning thing, even though there was no coolant temp issues, when I got out and smelled the exhaust it def smells like coolant to me. I have some bubbles coming up in the overflow tank so I don't know if that is just air in the system or not. It's just confusing because the leak down was fine originally, although it did "overheat" prob for a brief period since when the fans weren't working. The overflow bottle looks milky, but not brown. I'll check the oil but last time it wasn't milky at at all, it was totally clean.

So, I'm somewhat excited to have it up here but also not totally out of the woods so I can't really totally enjoy the car until I figure out these issues.

Ben
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Old 10-23-2012, 01:11 AM   #239
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I tried to do a datalog on the way home from the gym but apparently it didn't start... I'll have to grab more data tomorrow.

First time parking at work!


Got an alignment today as well from Jeff the Alignment Guy. Very reasonable rates, I went with zero toe and -1.5 in the front and it was already at basically -1.5 in the rear. Only $50 for a professional alignment seems like a good deal to me.





I am hoping to figure some stuff out tomorrow with the misfiring/stuttering issues, it definitely doesn't seem to be consistent from the initial runs though.

Ben
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Old 10-28-2012, 12:15 AM   #240
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A little update. I have about 250 miles on the car and so far besides the stuttering issue it has been perfectly fine. I was having logging problems with my AP but I think discovered I was just trying to log too many parameters at once.

Here is an example of the issue I am seeing: Basically all you need to look at are the two columns on the left, A/F ratio and boost and you can see the problem.

Code:
	A/F RatioBoost (PSI)	Calculated Load (g/rev)Closed Loop Sw. (on/off)	Coolant Temp (∞ F)	Feedback Knock (∞)	Fine Knock Learn (∞)	Fuel Pump Duty (%)	Ignition Timing (∞)	Inj. Duty Cycle (%)	MAF (g/s)	MAF Volt. (V)	Roughness Cyl 1 (count)	Roughness Cyl 2 (count)	Roughness Cyl 3 (count)	Roughness Cyl 4 (count)	RPM (RPM)	Throttle Pos. (%)	14.7	-10.21	0.27	On	181.4	0	-0.7	33.33	39.5	5.59	14.73	1.92	0	0	0	0	2892	9.41
	15.27	-9.58	0.33	On	181.4	0	-0.7	33.33	42	6.25	15.92	1.96	0	0	0	0	2938	10.2
	14.81	-8.8	0.38	On	181.4	0	-0.7	33.33	44.5	7.57	19.23	2.08	0	0	0	0	2963	11.76
	14.01	-7.24	0.51	On	181.4	0	-0.7	33.33	45.5	10.76	30.21	2.36	0	0	0	0	2968	17.65
	14.24	-2.99	0.87	On	181.4	0	0	33.33	38.5	17.75	63.49	2.94	0	0	0	0	3047	41.18
	14.7	2.47	1.53	On	181.4	0	0	66.67	27	25.64	86.94	3.26	0	0	0	0	3197	85.49
	13.21	6.94	1.98	On	181.4	0	0	100	18.5	36.87	116.72	3.5	0	0	0	0	3310	85.88
	12.17	9.9	2.26	On	179.6	0	0	100	16	42.78	134.39	3.7	0	0	0	0	3473	85.88
	12.63	10.89	2.39	On	179.6	0	0	100	15.5	46.78	151.1	3.84	0	0	0	0	3654	85.88
	11.83	11.25	2.37	Off	179.6	0	0	100	17	56.32	152.14	3.84	0	0	0	0	3893	87.45
	12.86	11.3	2.38	Off	179.6	0	0	100	17.5	59.32	163.69	3.9	0	0	0	0	4096	92.55
	16.54	11.42	2.4	Off	179.6	0	0	100	18	64.07	170.51	4	0	0	0	0	4273	87.84
	16.42	11.1	2.37	Off	179.6	0	0	100	18	64.57	172.74	3.98	0	0	0	0	4411	84.71
	16.19	10.32	2.3	Off	179.6	0	0	100	20.5	63.69	171.61	3.98	0	0	0	0	4511	61.96
	15.04	-10.55	0.21	On	179.6	0	0	33.33	40	2.96	7.63	1.54	0	0	0	0	4537	5.88
	16.42	-12.49	0.05	Off	179.6	0	0	33.33	40	2.89	3.64	1.26	0	0	0	0	4516	1.96
	20.33	-12.65	0.04	Off	179.6	0	0	33.33	24	2.8	3.43	1.26	0	0	0	0	4390	2.75
I swapped my fuel filter for a new one since it was cheap and easy which did nothing. There was very minor roughness on cylinder 1 in one log so Jarrad from PDXTuning thought maybe that injector is the issue. It is possible, I may try and hook up a fuel pressure gauge and see if pressure is dropping as I accelerate. I am thinking maybe the fuel pump is not sealing in the housing or something.


Also, a little feedback on driving it so far. It is sweet, a lot cooler than my old toyota pickup and even at part throttle is way quicker and I can actually accelerate onto the highway haha. The suspension is not bad but I agree with omahasubaru when he said the Bilsteins are overdamped for sure. I am getting clunking in the rear at times and I'm not sure if that is just my sway bar or not.

At 6'4" tall I am going to need to find some seat rails to lower my Spec C seats because my head is basically touching the roof if I were to sit straight up. If I can't get some diff seat rails I'll prob just run my stock seats even though I don't really want to do that since they are leather and it will be winter soon.

Gas mileage so far was not too hot, about 21mpg and that was pretty much all cruising.

My cruise control doesn't work, I need to clear that code and see if that will allow it to work. If not then I will probably have to do some wiring to get it to work correctly.

Also, still haven't had a chance to hook up the underseat subwoofer. However, I did get an indoor parking spot(Hooray!) at my apt so that should be a job I can do one of these days and not freeze.

I am hoping the coolant issue is not an issue, I ran my heater on high and then once the car cooled down I filled the overflow tank to full, it's still basically at that line but it has moved down probably an 1/8" so I'll keep monitoring that situation.

I am looking forward to the day when I can go WOT and have no issues. The good thing is I am not getting really any knock so it should not have hurt the engine at all so far.

Ben
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Old 10-28-2012, 05:31 PM   #241
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I am now subscribed to this build.
Your H6 build was soul-touching & I believe that this is a perfect new beginning
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Old 10-31-2012, 09:02 AM   #242
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You're logging with an AP?

A. your log samples are WAY too far apart to be sure on anything right now.
B. I wouldn't be so sure that you're engine will last at this rate.

I'd do some more logs and just log engine speed, engine load, a/f, M. relative pressure or MAP, flkc, fbkc, knock count if its available(this is 16bit or 32bit ecu?)


Something isn't right and I'd stay out of boost if I was you.
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Old 10-31-2012, 09:25 AM   #243
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Congrats BEN! It's been a long road. Kudos to you for sticking with it and finishing it up!
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Old 11-01-2012, 10:25 PM   #244
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Quote:
Originally Posted by SBW View Post
You're logging with an AP?

A. your log samples are WAY too far apart to be sure on anything right now.
B. I wouldn't be so sure that you're engine will last at this rate.

I'd do some more logs and just log engine speed, engine load, a/f, M. relative pressure or MAP, flkc, fbkc, knock count if its available(this is 16bit or 32bit ecu?)


Something isn't right and I'd stay out of boost if I was you.
I logged less variables and still was not seeing knock events. It is a 16bit ecu I think, whatever the 2004 STi ecu's are.

I'm definitely not getting in to boost as much as possible, effectively I'm staying in closed loop prob 99% of the time.

Quote:
Originally Posted by omahasubaru View Post
Congrats BEN! It's been a long road. Kudos to you for sticking with it and finishing it up!
Thanks Jonathan! It has definitely been a long road, once I sort the fueling issue out it will be great. The suspension will clunk over some harder bumps, not sure if that is my sway bars or what but I dislike it.

I'll try and troubleshoot the fuel issue this weekend. I'm putting money on something with the fuel pump/strainer and I'm hoping it's an easy fix whatever it is...

Ben
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Old 11-02-2012, 12:13 AM   #245
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Just stopping by to say it's absolutely awesome to see this almost complete. Congrats Ben! Can't wait too see some video.
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Old 11-04-2012, 02:29 PM   #246
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thanks Mitch!

So I drove back home Friday to try and troubleshoot the fuel issue. Ironically, about 5 miles from home I started to get a couple misfires, fuel was low but the fuel light wasn't on so I should have had at least 2 more gallons I would think. I am thinking "hey this could be a positive and proving there is something up with the fuel pump not sealing or the strainer is clogged". The car died 2 miles from home right on the off ramp. Luckily I only had to walk down the hill 100ft to the gas station haha. I put like 1.5 gals into the car and it fired right up I drove it to the station and filled it about 3/4 full and it was fine.

I was hoping when I pulled the pump the next day I would see something obvious but there really wasn't anything obviously wrong. The strainer didn't seem to be clogged and the pump seemed to still be secured in the rubber grommet so I don't think suction was any problem.

At this point I'm thinking it could be one of two things. A voltage drop on the pump as I accelerate, or crap in the gas tank. I am not sure if this occurred when it sat for so long after the H6 project or what but there seems to be rust colored crap all in the tank, in that it is making the gas in the tank murky. I noticed also that it was gettting past the strainer as I could pour it back out of the pump housing. I am not sure if that little reservoir on the housing is a filter as well but I could def spray brake clearn back through the fuel outlet and get the brownish stuff to come out.

I need to test the voltage theory as I was unsure how to best monitor that, it may be an option on the accessport but I'm not certain, that would be nice if it is. It very well could be all the crap in the tank but it seems to drive fine under more normal conditions(typically less than 50% throttle and less than 100% duty cycle on the pump). When the tank is over 1/4 is drives fine and I drove back up last night with no issues going pretty much 70mph the whole time. Again this could be due to the contaminants being much less concentrated once there is more fuel in the tank or it could be electrical.

To rule out it being a map issue I flashed the stage 1 map on and it still has the hesitation. It also still had the hesitation when I pulled everything out and re-installed it.

I am considering getting a walbro or DW200 pump and throwing that in there to see if that solves it however that could just be a bandaid and not address the real problem so I need to check voltage first.

Any ideas would be appreciated or other things to check.

Ben
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Old 11-06-2012, 11:52 AM   #247
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Glad to see her up and running Ben. It makes me want to pursue a swap in my car...

Would love to see a complete build/parts list when you get the chance. I'm sure others would be extremely greatful as well.

I'm sure it's a blast to drive...
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Old 11-08-2012, 09:12 PM   #248
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Let me know your thoughts on that sound ordnance sub. I was thinking about getting one.
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