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Old 01-16-2017, 08:35 AM   #1
BChoi
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Join Date: Oct 2015
Location: Vancouver, BC, Canada
Default Modest EJ205 build

Hey guys, I own a 2004 WRX Wagon. Couple months ago my clutch went out which lead me to pulling my engine out. Since then I have decided it would be a fun project to do a complete rebuild and do some modest upgrades to make it a fun DD. My goal is not to push 300whp but instead to pretty much refresh everything back to new and keep the car reliable with little bit of extra fun.

Here is an incomplete list of mods going into this build (I've lost track at some point)

Manley Platinum Series 92.5mm Forged Piston (8.5:1 Compression)
Manley H Beam Connecting Rods
ACL Race Series Main Bearings
ACL Race Series Rod Bearings
Killer B Oil Pickup Tube
Killer B Oil Baffle
OEM STI Oil Pan
Kartboy Pulley
Ferrea Valve Locks
Manley Race Series 32mm Intake Valves
Manley Race Series 36mm Exhaust Valves
GSC Power-Division Viton Valve Stem Seals
ARP Head Stud Kit 11mm
STI Pink Fuel Injectors
DeatschWerks DW200 Fuel Pump
GFB Hybrid BOV
GrimmSpeed EBCS
Melett TD04 Turbo Rebuild Kit (Super Back)
ARD Tuning TD04-19T Conversion Kit (Subaru)
ARD Tuning 11 Blade TD04L Turbine Wheel
SteamSpeed Journal Bearing Turbo Oil Line
Tomei Expreme Unequal Length Exhaust Manifold & Uppipe
GrimmSpeed Catted Divorced Ceramic Coated 3 Inch Downpipe
Invidia N1 Street 3" Exhaust
K&N Typhoon Short Ram Intake
Tomei Silicone Turbo Inlet Hose
Zerolift TGV Delete
Mishimoto TMIC W/ Hoses
Mishimoto Aluminum Radiator
Mishimoto Ancillary Hose Kit
Mishimoto Radiator Hose Kit
ACT StreetLite Flywheel (13.9lbs)
Southbend Stage 2 Clutch (345ft/lbs @ Crank)
GoodRidge Stainless Steel Coated Clutch Line
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Last edited by BChoi; 01-16-2017 at 09:06 AM.
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Old 01-16-2017, 08:54 AM   #2
BChoi
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Join Date: Oct 2015
Location: Vancouver, BC, Canada
Default

Here are some progress that's been made so far:

When I started on this day 6 months ago I never knew this would turn into a full blown project


First time working on a car myself and after many hours of struggle I finally had the engine out


Got it to my friend's place to start the teardown


Upon disassembly I found that the bores were out of shape by quite a lot and one had some damage. This is when I knew a full rebuild was needed.


So, out with the old and in with the new!
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Old 01-16-2017, 08:56 AM   #3
BChoi
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Location: Vancouver, BC, Canada
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19T turbo upgrade for the TD04 from ARD which has a custom billet compressor wheel that doesn't need the CHRA machined to fit. Got the CHRA cleaned and the exhaust housing ceramic coated. CHRA taken back after rebuild for balancing.















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Old 01-16-2017, 09:02 AM   #4
BChoi
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I had a local shop rebuild my engine for me. Will be picking it up tomorrow so that's pretty much where this build log will begin.













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Old 01-19-2017, 07:41 PM   #5
SeanL15
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Chapter/Region: NWIC
Vehicle:
2005 WRX
Blue

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How much did the rebuild cost you?
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Old 01-19-2017, 11:25 PM   #6
BChoi
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Quote:
Originally Posted by SeanL15 View Post
How much did the rebuild cost you?
2000CAD so 1500USD? There was also cost of couple new buckets for valve lash and x bearings for rods and crank that was included in that along with some initial work I had gotten from them.
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Old 01-20-2017, 10:00 PM   #7
BChoi
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Intake assembly finished







Going to be finishing up the oil pan and timing component this weekend



Mocked up

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Old 01-25-2017, 05:21 PM   #8
wingman358
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Member#: 146760
Join Date: Apr 2007
Chapter/Region: MAIC
Location: N. Virginia
Vehicle:
2004 WRX Wagon
WRB

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Nice. Similar to a build I'm planning.

What bearing clearances are you running? PTW? and did you have the case halves or heads decked?
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Old 01-26-2017, 07:07 AM   #9
Titter
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Join Date: Mar 2015
Chapter/Region: International
Location: Ontario, Canada
Vehicle:
2002 WRX Wagon
EJ207 Spec C 4EAT

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composite tgv's?

make sure to add a good ground from your intake manifold to your block as there is no longer a metal connection between them.

nice lookin build. good luck with it
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Old 02-01-2017, 02:31 AM   #10
BChoi
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Old cam sprockets were starting to crack and chip so they were replaced


Timing belt installed


Starting to look like a motor with oil pan and headers installed


Subaru feel intensifies

Last edited by BChoi; 02-01-2017 at 11:48 AM.
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Old 02-01-2017, 02:33 AM   #11
BChoi
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Quote:
Originally Posted by Titter View Post
composite tgv's?

make sure to add a good ground from your intake manifold to your block as there is no longer a metal connection between them.

nice lookin build. good luck with it
Yup already on it.

Quote:
Originally Posted by wingman358 View Post
Nice. Similar to a build I'm planning.

What bearing clearances are you running? PTW? and did you have the case halves or heads decked?
Stock clearances with new oem oil pump. Had to use some X bearings to get correct tolerances on both the main and rod bearings due to wear. Crank was polished and all internals dynamically balanced.
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Old 02-01-2017, 06:04 PM   #12
wingman358
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Join Date: Apr 2007
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Location: N. Virginia
Vehicle:
2004 WRX Wagon
WRB

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Nice, when does it go back in the car?
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Old 02-01-2017, 06:49 PM   #13
GK1707
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Chapter/Region: Tri-State
Location: Queens
Vehicle:
V7 WRX

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"Modest"....lolz
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Old 02-01-2017, 10:02 PM   #14
BChoi
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Quote:
Originally Posted by GK1707 View Post
"Modest"....lolz
Hahahahaha modest in power upgrade
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Old 02-01-2017, 10:03 PM   #15
BChoi
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Quote:
Originally Posted by wingman358 View Post
Nice, when does it go back in the car?
I'm off to race longboards in Australia until end of February so early March probably.
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Old 02-02-2017, 12:15 PM   #16
jacksonwrx
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Just diesel swap it best option
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Old 02-02-2017, 06:08 PM   #17
lavid2002
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Clean build. This is how to rebuild. What's up with the cam sprocket bolts?
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Old 02-03-2017, 12:23 AM   #18
BChoi
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Quote:
Originally Posted by lavid2002 View Post
Clean build. This is how to rebuild. What's up with the cam sprocket bolts?
Thank you, I take pride in being a perfectionist.
TiC Cam Bolts so you don't ever have to deal with the pesky allenhead bolts that easily strip, instead you get a proper 17mm.
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Old 02-09-2017, 03:52 AM   #19
kris142b
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Chapter/Region: MWSOC
Vehicle:
2002 WRX
Sedona Red Pearl

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*breathes heavily
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Old 03-11-2017, 02:51 AM   #20
Derfud
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Join Date: Aug 2008
Chapter/Region: VIC
Location: White Rock
Vehicle:
2003 WRX Sedan
Black

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Quote:
Originally Posted by BChoi View Post
I had a local shop rebuild my engine for me. Will be picking it up tomorrow so that's pretty much where this build log will begin.
Which shop did you use to do the rebuild? I'm considering something similar for my 03 WRX (assuming you are in the lower mainland).
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Old 03-21-2017, 12:30 AM   #21
BChoi
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Quote:
Originally Posted by Derfud View Post
Which shop did you use to do the rebuild? I'm considering something similar for my 03 WRX (assuming you are in the lower mainland).
Terry Bride Racing in Richmond did my rebuild.
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Old 03-21-2017, 12:36 AM   #22
wingman358
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Member#: 146760
Join Date: Apr 2007
Chapter/Region: MAIC
Location: N. Virginia
Vehicle:
2004 WRX Wagon
WRB

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O shoot you're back from Australia. How was it mate? How excited are you to get boostin?
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Old 03-21-2017, 07:28 AM   #23
Titter
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Join Date: Mar 2015
Chapter/Region: International
Location: Ontario, Canada
Vehicle:
2002 WRX Wagon
EJ207 Spec C 4EAT

Default

Quote:
Originally Posted by Derfud View Post
Which shop did you use to do the rebuild? I'm considering something similar for my 03 WRX (assuming you are in the lower mainland).
Quote:
Originally Posted by BChoi View Post
Terry Bride Racing in Richmond did my rebuild.
FYI: thats Richmond, British Colombia... not Richmond, Virginia. nowhere near lower mainland. its upper coldland lol
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Old 03-21-2017, 10:36 PM   #24
Hooligan907
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Vehicle:
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Rally Blue

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This is such a sweet build. Foaming at the mouth to see it finished.
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Old 03-23-2017, 04:21 AM   #25
mattzke
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looks so good :O
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