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Old 08-27-2017, 05:59 PM   #26
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

http://i.imgur.com/CjGOEdh.jpg

Finally tracked down a hoist and engine stand! Time to get to work!!

http://i.imgur.com/lAsL1gU.jpg

Wrapped up the intake manifold with a rachet strap.

http://i.imgur.com/XlmJ55T.jpg

Jack stand under the tranny to reduce load to the input shaft.

http://i.imgur.com/V0MU5Ts.jpg

After a little pump to raise the motor, time to separate using thin bladed screwdrivers and a hammer.
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Old 08-27-2017, 06:03 PM   #27
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

http://i.imgur.com/5OFwYxi.jpg

More pics of splitting the block from the tranny.

http://i.imgur.com/sJDeQco.jpg

It's free!

http://i.imgur.com/pUObUQX.jpg

Bolted to a stand!

http://i.imgur.com/QuQ4LWJ.jpg

Obligatory stand where the motor used to be shot.

Next part of the plan is to set up a meeting with my engine builder and see what all they need from the old motor to start building the new one. In the mean time, I will try to remove some of the parts underneath the car that are rusty and try the whole electrolysis rust removal thing.
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Old 04-07-2018, 06:17 PM   #28
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

https://i.imgur.com/kOon68x.jpg
Big update!

Yesterday I took delivery of my rebuilt EJ257 from Area 1320 Motorworks in Nazareth, PA.
The motor was rebuilt with a nice list of goodies!
-Area1320 Spun Bearing Special, an OEM loaded shortblock with Manley forged pistons
-Subaru OEM Complete Gasket Kit
-11mm oil pump
-oil pump union
-2.5L oil pan
-Killer B Ultimate oil pick up
-Aluminati TGV Delete Housing
-Perrin 02-07 Subaru STi Black Turbo Inlet Hose
-Timing Belt Component Kit with Water Pump
-Comp Clutch Sti Subaru Steelback Brass Plus Clutch Kit
-Matching Flywheel Resurfacing
-Matching cylinder head
-Misc Hoses

https://i.imgur.com/U704Ndr.jpg
https://i.imgur.com/sOhr6Ee.jpg
https://i.imgur.com/POFSOE3.jpg
https://i.imgur.com/YXpijS6.jpg

Now that I have the motor, I've got some work to do underneath the car with mild rust removal and some extra parts like a new radiator, new subframe (which is rusting out), a few extra hoses, sensors and belts while the motor is out.

Looking forward to the next couple months!
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Old 05-25-2018, 04:36 PM   #29
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Weather's getting nice, a couple more parts and goodies are trickling into my mailbox. Time to get to work.

Installed new STi Motor Mounts:

https://i.imgur.com/RYyUNNk.jpg
https://i.imgur.com/X8jDNPR.jpg
https://i.imgur.com/68xIiYq.jpg

Also, I went to put my new clutch in but stripped a pressure plate bolt head when torquing them down. Luckily my buddy's left handed drill bit spun it right out!

https://i.imgur.com/bUqEB97.jpg
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Old 05-25-2018, 04:38 PM   #30
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Also took the front subframe off. It's getting pretty rusty thanks to NEPA winters and salt on the road.

https://i.imgur.com/yYGnZvl.jpg

It wasn't the worst shpae I've seen for a subframe after searching the internet, but I figured while the motor was out I would replace it before it rotted away and prevented me from passing inspection.

https://i.imgur.com/28kM0Li.jpg

The subrame bolts were relatively unpleasant to get out. One broke.

https://i.imgur.com/ReHdqnJ.jpg
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Old 05-26-2018, 12:44 AM   #31
rayd3rz
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Member#: 486430
Join Date: May 2018
Vehicle:
2011 STI
Matte White

Default Love it!

Quote:
Originally Posted by Dash_Martino View Post
http://i.imgur.com/5OFwYxi.jpg

More pics of splitting the block from the tranny.

http://i.imgur.com/sJDeQco.jpg

It's free!

http://i.imgur.com/pUObUQX.jpg

Bolted to a stand!

http://i.imgur.com/QuQ4LWJ.jpg

Obligatory stand where the motor used to be shot.

Next part of the plan is to set up a meeting with my engine builder and see what all they need from the old motor to start building the new one. In the mean time, I will try to remove some of the parts underneath the car that are rusty and try the whole electrolysis rust removal thing.
This thread definitely gives me the motivation I needed to get to work on mine I have a 2011 sti and want all the goods in an 05 because that is my dream car keep it up and canít wait to see the end results!
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Old 07-03-2018, 01:38 PM   #32
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Update time!

Vacation time for me, got a few days off. It's hot as hell, but it's somewhat shaded in my garage, so time to get to work!

Time to put the clutch in, no broken bolts this time.

Cleaned flywheel:
https://i.imgur.com/I1DhXiN.jpg

Clutch disc with alignment tool:
https://i.imgur.com/CR2rw1Q.jpg

Cleaned pressure plate:
https://i.imgur.com/PLDqLS0.jpg
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Old 07-03-2018, 01:41 PM   #33
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Ordered new clutch bolts for such a special occasion. Didn't break the bank, they were only about $0.50 a piece:
https://i.imgur.com/T1m4GnG.jpg

Pressure plate installed. Bolts torqued to 12 foot pounds, no problem.
https://i.imgur.com/OZYIEz7.jpg

Also new throw-out bearing installed. Went relatively easy, was surprised:
https://i.imgur.com/Nlom5DS.jpg
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Old 07-03-2018, 01:43 PM   #34
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Other minor improvements today. Installed a new turbo oil return line, which is much easier with the motor remove from the car:

https://i.imgur.com/uCLnlv1.jpg

Also a new positive battery terminal:
https://i.imgur.com/xOEBdDE.jpg

That's it for now. Ordered the new subframe, got it for about $350. Glad I checked to see if it was STi specific (it is!)

Right now I could drop the motor in if I wanted, but I'd still like to clean the engine bay and install the subframe before I put the motor in and run out of room to work easily. More updates by the end of the summer!
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Old 07-03-2018, 02:34 PM   #35
Scuby04STi
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Member#: 328635
Join Date: Aug 2012
Chapter/Region: NWIC
Location: Portland*
Vehicle:
2004 STi GTX3076R
Rally Blue

Default

Well if you wanted to pay the shipping I have one of those U braces off my '04 that's from rust free Oregon, LOL. That is if your able to cancel the one you ordered. I was just about to cut it up and scrap it.
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Old 08-12-2018, 07:58 PM   #36
Dash_Martino
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Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

So my buddy helped me build a table for my back porch using a tabletop I found at my house and old EJ motor parts... These are the results:

https://i.imgur.com/fq63eSM.jpg
https://i.imgur.com/iT4odk0.jpg
https://i.imgur.com/YTOZ6Dh.jpg
https://i.imgur.com/jLQmmbD.jpg
https://i.imgur.com/IxdV2oH.jpg
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Old 08-12-2018, 08:52 PM   #37
Bewrx6
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Member#: 487574
Join Date: Jun 2018
Chapter/Region: BAIC
Location: Watsonville, Ca
Vehicle:
2002 Wrx
Silver

Default

Quote:
Originally Posted by Dash_Martino View Post
So my buddy helped me build a table for my back porch using a tabletop I found at my house and old EJ motor parts... These are the results:

https://i.imgur.com/fq63eSM.jpg
https://i.imgur.com/iT4odk0.jpg
https://i.imgur.com/YTOZ6Dh.jpg
https://i.imgur.com/jLQmmbD.jpg
https://i.imgur.com/IxdV2oH.jpg


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Old 08-28-2018, 09:19 PM   #38
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Exciting times! New subframe goes in. Painted it with undercoating spray, got brand new bolts from subaru and torqued them down to spec.
https://i.imgur.com/xoJxJ2z.jpg

Next up, time to drain transmission fluid and put fresh stuff in. Was able to get the bigger differential bolt off no problem, but the transmission oil pan nut decided to strip no matter what I tried.
https://i.imgur.com/rVc62dE.jpg

Decided to yank the pan and yank the magnet as many people recommended:
https://i.imgur.com/uWQzCMA.jpg
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Old 08-28-2018, 09:21 PM   #39
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

New pan from Subaru with an updated strip-resistant drain bolt:
https://i.imgur.com/860HpYO.jpg

Installed and torqued down:
https://i.imgur.com/wnVBUn3.jpg

Fresh Motul 75W90 300 LS!
https://i.imgur.com/Yc4rLNV.jpg
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Old 08-28-2018, 09:23 PM   #40
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Sprayed down the engine bay with some degreaser and hosed off the engine bay:

https://i.imgur.com/yyQAWh3.jpg

https://i.imgur.com/DqBQMY7.jpg


Can't really think of anything else left to do but drop the motor in (but I am willing to hear some suggestions while the motor is out!)
https://i.imgur.com/f0Ia5It.jpg

Thanks for all your help and support, stay tuned.
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Old 09-09-2018, 08:18 PM   #41
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

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Old 09-10-2018, 02:53 PM   #42
BlueSTI4Me
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Member#: 34361
Join Date: Mar 2003
Chapter/Region: MWSOC
Location: MI
Vehicle:
04.7 STI
WRB IG @got2boostit2

Default

Nice work on this 2004 STi.
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Old 09-21-2018, 10:55 PM   #43
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

After getting the motor in, I discovered that my clutch wouldn't mount to my throw out bearing thanks to the lame two-piece hub ring that broke on installing the motor. Unfortunately this meant that the motor had to come out again. Opted to get an ACT Monoloc:
https://i.imgur.com/WIcl0El.jpg
https://i.imgur.com/Nj85dx5.jpg
Highly recommended. If doing a clutch install, pony up and pick one up, totally worth it for the peace of mind.

Motor is in. Again.
https://i.imgur.com/rABmVBP.jpg
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Old 11-25-2018, 04:31 PM   #44
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Update Time!

New starter is in:
https://i.imgur.com/f21j8tg.jpg

New heater core hoses installed:
https://i.imgur.com/TeigPZy.jpg

Fuel lines re-installed:
https://i.imgur.com/KstyPw8.jpg
Note: Label them. I didn't. Took me forever to figure out! Learn from my mistakes!
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Old 11-25-2018, 04:36 PM   #45
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Wiring harness reconnected:
https://i.imgur.com/9cPV3GF.jpg
https://i.imgur.com/bxI1PCz.jpg

O2 sensor re-installed with bracket to keep the wire safe:
https://i.imgur.com/iTLAOEx.jpg

And downpipe (mostly) reinstalled. Have to find one more 14 mm nut.
https://i.imgur.com/fDxTeSz.jpg

Next big hold up: I went to re-install the brackets for the power steering lines, but I'm missing a black bracket that sits just below the coolant expansion tank. It has holes for a few 10 mm nuts to attach the brass PS line brackets. Any help with a part number or point in the right direction would be huge! Thanks!
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Old 12-15-2018, 01:58 PM   #46
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Updates!
Installed the 2008+ WRX expansion tank, as the metal one on mine was kind of cruddy. Also zip tied my power steering lines together, as there is no space for the brackets since the TGV deletes have no mounts for the brackets.
https://i.imgur.com/4AxDgHi.jpg

Brand new alternator:
https://i.imgur.com/O4e7OVC.jpg

And a broken green clip to boot:
https://i.imgur.com/D3ZZVTy.jpg

Not pictured: the Power Steering O-Ring Fix because why not for $5!
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Old 12-15-2018, 02:01 PM   #47
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Cleaned up and re-intalled my K & N Intake

https://i.imgur.com/4rtzEMv.jpg

and plugged in my Mishimoto Radiator:
https://i.imgur.com/WT72B9z.jpg

Next up on the to do list:
-Trim and fit radiator hoses
-Drain the old fuel, install new fuel pump
-New gaskets for intercooler y-pipe
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Old 12-23-2018, 07:13 PM   #48
Dash_Martino
Scooby Newbie
 
Member#: 78728
Join Date: Jan 2005
Chapter/Region: Tri-State
Location: Jim Chunk, PA
Vehicle:
04 STi
PSM

Default

Put in a new Walbro 255 Fuel Pump today
https://i.imgur.com/Tr3xfEQ.jpg
https://i.imgur.com/Pbx8HJS.jpg
https://i.imgur.com/SeYmlsa.jpg

Also cleaned the crap off the plate on top.

Next:
- Intercooler cleaning / y pipe gasket fitting
- Clean / re-paint hella supertones
- Heater core flush because might as well
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Old 12-23-2018, 10:05 PM   #49
BlueSTI4Me
Scooby Specialist
 
Member#: 34361
Join Date: Mar 2003
Chapter/Region: MWSOC
Location: MI
Vehicle:
04.7 STI
WRB IG @got2boostit2

Default

Nice work there bud.
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Old 12-24-2018, 01:24 PM   #50
hellavetica
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Member#: 436595
Join Date: Dec 2015
Chapter/Region: Tri-State
Location: NY.
Vehicle:
2007 STi
UGM.

Default

Great progress so far ! But I would suggest re-using the old fuel pump sock instead of using the included Walbro sock as theres a lot of people with bad experiences with them.
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