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Old 10-03-2012, 01:23 PM   #1
claythrow
Scooby Specialist
 
Member#: 283663
Join Date: May 2011
Chapter/Region: NESIC
Location: Boston
Vehicle:
2004 STI
Root Beer

Default USDM 04 WRX 205 rebuild suggestions

Ok. So after talking to several people about this I'm going to rebuild the motor myself. (Spun rod bearing/s….how do I know w/o taking the motor apart? I just know what it sounds like) I haven't removed or cracked the engine apart yet. I'm quite mechanically inclined, the whole car is practically new which I did myself and I'm pretty confident I can do it.


I'm getting rough estimates for $2500-$3k to have it done but if I can do it myself for as much or cheaper and build up my tool arsenal while I'm at it, that is a win/win to me. I have another vehicle, a garage, and I'm out of work at the moment so none of those are a problem.

What is a problem is that this will be the third motor going in this car and my wife has about had it. After this, any more costly repairs and she wants the car gone. For what it's worth, the first motor was blown by the previous owner. Subaru replaced it under warrantee. The second motor I blew because the oil pump failed. Oddly enough both motors went at 60k. So I want to rebuild it bulletproof. Everything on it is stock except the exhaust.It's totally cat less w/ tomei racing headers and UP, cat less DP and stock STI in the final link. (I know it's a little restrictive but it keeps it quiet) EVERYTHING else on the car is 100% stock.

I have the best machine shop in New England right around the corner for any machine work that needs to be done.

Where I need help is I don't know what parts to buy once I open the case. I realize you don't know either as you don't know whats ok or what's destroyed but covering the basics, what parts should I be looking at? Sizes are important too as I was looking at some of the internals and there are so many sizes available and I don't know what my engine uses.

Can you guys give me some ideas of what to look at to rebuild this sucker better than Subaru appears to do it? I'm tired of the rod problem. I know the previous owner and neither him nor I beat on or race the car. Sure we zip around some fun corners when there are no cops around but neither of us beat on this car more than I do my wife's corolla. No more Subaru short blocks for me, I don't trust them.

So, along with sizes, what pistons, cranks, valves, valve springs, case/head bolts etc would you buy so that I can look into them. Ideally I could rebuild the engine and have enough left over for a larger turbo. Nothing outrageous, but not a TD04 so I want to build an engine that is future proof. If I can rebuild it, accumulate knowledge and some tools in the process and get a used larger turbo for $3k I would be on cloud 9. Plus cars are where my heart is, I'll be doing this the rest of my life so I want to rebuild it myself…just to do it, does that make sense?

Can you help by giving me suggestions. Not only on what parts but websites to get them? I can learn as I go and I've got help, but where to start…specifically what parts to suit my purposes I turn to the veterans for suggestions. These are all "what if" suggestions till I crack it open, but it would be helpful to know ahead of time what parts I would want should I happen to need them.

The main goal is a strong motor that will handle a larger turbo (a used STI turbo of one generation or another, nothing gigantic) and that I can have some confidence in as so far, these 205 short blocks have some weak links. If I don't correct them this time around I'll be driving a 2002 corolla for the rest of it's undoubtedly immortal life. As it is I'm dipping in to my 401k to pay for this motor. Thanks for your help and the help I've already received from the gentlemen in Jax FL.
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