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Thread: Grafton's 07 STi

  1. #31
    SLi Supporter Grafton's Avatar
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    Quote Originally Posted by Yamazaki View Post
    With the overbore, what will your new displacement be?
    2.5L still,
    old bore was 99.5mm x 79mm stroke x 4 cylinders = 2458cc
    new bore 99.75 x 79mm stroke x 4 cylinders = 2470cc
    12cc displacement bump or .012 L

    I got heads today!, the valves were reground due to pitting, and the heads resurfaced by .003"





    While waiting on the copper gasket spray to dry I added some Piston Wisdom™

    Jeremy Clarkson inspired



    Copper coated head gasket in place:


    Heads installed:




    Cams installed to check clearances




    Thanks to the re-grind only one valve was in spec, going to mic the shims Thursday and find out how many I have to order and if I can just swap some around.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  2. #32
    SLi nOOb Alphius's Avatar
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    Shouldn't have to mic the lifters, they're all labeled with their sizes on the underside.
    99 Legacy GT WRX - Now for sale!
    05 Legacy GT Limited 5MT Wagon - Stock-ish.
    02 Outback Limited 5MT - Lifted, Dual Range
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    85 Silverado - Low and slow tow rig

  3. #33
    SLi Supporter Grafton's Avatar
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    Quote Originally Posted by Alphius View Post
    Shouldn't have to mic the lifters, they're all labeled with their sizes on the underside.
    Doing the rebuild by the book, book calls for it. I'm hoping that they are right on the money with the labels.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  4. #34
    SLi nOOb Alphius's Avatar
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    Got it, no harm in being thorough! For some reason a lot of people don't realize they're marked so I figured I'd chime in. Looks like you're doing a good job on the rebuild!
    99 Legacy GT WRX - Now for sale!
    05 Legacy GT Limited 5MT Wagon - Stock-ish.
    02 Outback Limited 5MT - Lifted, Dual Range
    84 Camaro Z28 - LS1/6-speed
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  5. #35
    SLi Supporter Grafton's Avatar
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    ^Thanks

    I mic'd them today, luckily only going to need to buy 11, but most of the lifters were .01-.03mm smaller than how they were marked so a 510 was really a 507 or a 500 was a 499
    Last edited by Grafton; 10-02-2015 at 10:49 PM.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  6. #36
    SLi Supporter Grafton's Avatar
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    Lifters ordered

    Threw in the block heater


    and started wrapping the factory manifold, I'm planning on putting the heat shield back on, and possibly wrapping the crossover pipe, depends on how much 2" wrap I have after the up pipe.


    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  7. #37
    SLi Supporter Grafton's Avatar
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    Progress from today:

    Hit the manifold with sealant, the copper coated the gaskets




    Test Fit the valve covers



    Piping mess begins


    Also started cleaning the oil of of the TMIC, it was filthy.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  8. #38
    SLi Supporter Grafton's Avatar
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    The stock studs fought, after many broken bits I took it to an exhaust shop and they were able to get the damaged studs out
    Wrapped up and waiting to dry so I can give it a high temp silicone coating



    engine mounts on


    lots of blowby= oily turbo



    cleaned



    reassembled


    Secondary air injection and AC bracket
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  9. #39
    SLi Supporter Grafton's Avatar
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    I discovered that I ordered a WRX clutch kit instead of a STi kit, ordered the STi kit and shipped the WRX one back. Also discovered that the gasket kit didn't have the manifold to up-pipe gasket in it, and I grabbed a new 3" gasket for the downpipe to the midpipe.

    TGV's pulled, to be deleted soon. I've already tweaked my tvg closed map and disabled the codes



    passenger side head has correct clearance on the lifters and is put back together




    Need to order 3 more lifters to get the drivers side sorted
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  10. #40
    SLi Supporter Grafton's Avatar
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    Beginning of the TGV delete, pulling sensor motor combo


    grind down the screws



    removed butterfly's and rod


    Used a hacksaw to cut the divider walls out


    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  11. #41
    "FNG" Merc6's Avatar
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    Quote Originally Posted by Grafton View Post
    decided to clean the AVCS cam gears and ran into a problem, I stripped the torx out on the last bolt, made it into a slotted screw, and still had to fight it:


    the tear down


    there was very hard sludge buildup in the areas where the rotor didn't touch took a lot of carb cleaner but i got it out


    bottom of the cam rotor


    top of the cam rotor


    cleaned and read to re-assemble, not pictured the 6 spring seals that go into the rotor


    I replaced the 5 point torx with new hex bolts


    driver's side with the hex bolts



    got some of the next batch of parts in, set of new plugs and a clutch kit


    didn't expect the "pro-kit"
    When you cleaned these, did you re use the rubber gasket?


    Sent from my iFail using Tapatalk App

  12. #42
    SLi Supporter Grafton's Avatar
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    Quote Originally Posted by Merc6 View Post
    When you cleaned these, did you re use the rubber gasket?
    Had to, Subaru doesn't sell parts for the AVCS gears just the entire gear.


    FINALLY
    the engine is together!





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    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  13. #43
    "FNG" Merc6's Avatar
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    Quote Originally Posted by Grafton View Post
    Had to, Subaru doesn't sell parts for the AVCS gears just the entire gear.
    That's what it looks like I will be doing as well. I already replaced the exhaust cam gears trying to remove the bolts @ $75 each i'm not gonna replace those too.
    Quote Originally Posted by Grafton View Post
    FINALLY
    the engine is together!
    Good stuff! I like seeing builds finish.

  14. #44
    SLi Supporter Grafton's Avatar
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    Today's progress:

    Started removing the runner divider leftovers


    finished, even removed the little lip that the butterfly sits on


    Mock up of the TGV on the heads, the ports line up perfectly.



    Throw out bearing ready to go.


    Up pipe brackets installed


    Crank pulley installed


    The rest of the parts I'm waiting on are showing up on Monday, so the engine should be in the car Tuesday.

    Still have to replace the fuel filter, finish cleaning the TMIC and intake manifold, and complete the TGV delete.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  15. #45
    SLi Supporter Grafton's Avatar
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    Last parts arrived today, and the TGV deletes are finished.

    the bolt was about .5mm short on one side of the TGV but it seals up nicely:



    the motor/sensor side it was about 3mm too long, and had to be cut down and smoothed



    Turbo mounted and installed


    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  16. #46
    SLi Supporter Grafton's Avatar
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    FINISHED!!!

    I'm not a fan of the charge hoses I bought, the clamp for the BPV was too small and I had to reuse the stock clamp, and the TMIC elbow was too long and had to be trimmed to not bind up when mounting the intercooler

    ready to drop in




    bolted in


    ready to run, tested the block heater


    the post install hiccup was a small coolant leak on the oil cooler due to reusing the spring clamps
    other than that its works great

    now 960 miles of break in left to go
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  17. #47
    SLi Supporter Grafton's Avatar
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    Engine is broken in and running wonderfully. Finally got around to installing a set of rear sub-frame locking bolts



    Due to the freakish warm weather we're having this winter, I was able to install a little sound deadening in the car. I followed the cover 25% of the panel and you're good rule.

    Basically tapped around and found where the panels resonated the most and put some deaden-er there.
    Trunk:






    Under the rear seat:


    Not pictured because I was too lazy to take pictures are the outer doors skins, and the C pillar

    The car got some Christmas presents

    a pair of reverse light LED's

    Before


    After


    a pair of Brake light LED's put in the outer sockets


    and

    a controller for the LED strip in the wing to pulse the light then go steady
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  18. #48
    SLi Lurker foohfooh's Avatar
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    Hey that's super cool.

  19. #49
    SLi Supporter Grafton's Avatar
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    Brake light improvements don't help when the person that hits you comes from the side:







    Truck in the right lane, turned broadside into the left lane, I swerved into the oncoming lane and got tagged on the rear quarter.

    I'm not sure if he was trying to pull a U turn from the right lane to head South or if he was trying to get into the cemetery that's across the road.

    Now I get to deal with insurance BS while it gets fixed
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  20. #50
    SLi O.G. 98legwag's Avatar
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    That is lame. Hopefully it won't be too much a pain.

  21. #51
    SLi Resident fwa2500's Avatar
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    I saw that on facebook, that freaking sucks! Do you run a dashcam by chance?
    '11 Lexus CT200h - Feb. 2024-Present
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    '97 Legacy wagon (BK) TS-R wanna-be - Retired. Oct. 2007-Jan. 2015

  22. #52
    SLi Supporter Grafton's Avatar
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    ^ No, I have been wanting one... Going to do some serious shopping for one soon

    Pulled the fender back out so it's drive-able until the 22nd when the shop can get me in.
    Estimated damage = new wheel, door and quarter

    In the meantime, I DIY'd a set of hood struts:



    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  23. #53
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    great looking Sti, and I like you keep it stock after rebuild. it'll hold more value later down the road.

  24. #54
    SLi Supporter Grafton's Avatar
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    Finally got the car back, ended up getting a new quarter, door, rear bumper, and wheel. I'm extremely happy with the work, even though it got delayed a few times while parts were ordered and shipped.








    I was able to get both cars detailed inside and out yesterday, nothing better than clean cars after a days work:
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  25. #55
    SLi Supporter Grafton's Avatar
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    Finally got around to dealing with the serious amount of road rash the front of the car has.

    The fog light covers both had serious rash like this:


    The drivers side had issues from not having any mud flaps


    I got some touch up paint from drcolorchip.com and went to town


    The fog light cover came out ok, but where the clear coat is failing it is still noticeable up close


    The drivers side came out near perfect


    after touching up the aesthetics, I changed the transmission and rear diff oil finally with some Motul gear300. While I was under the car I installed a Group N transmission mount, Kartboy front and rear shifter stays, and a TiC piviot bushing. I attempted to change the shift linkage as well but the bushings were the wrong size.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  26. #56
    SLi Supporter Grafton's Avatar
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    More adventures with an old STi:

    Monday leaving work I hit a pot hole and it sounded like a sledge hammer hit the back of the car. and the ride through town was slightly bouncy. After a spine shattering ride home I found the rear passenger side wheel more extended than it should be:


    It would not compress at all, and after jacking the car up to inspect it the rear froze at full droop:


    after limping the car to the garage, with replacement struts in hand, I found that the shock had blow and filled the strut with oil, not allowing it to compress:




    The surprise came from the drivers side, the spring perch was sitting about a half inch lower than it should and had a non factory speed hole:




    I also replaced the front struts and put in some group n top hats to replace the cracked and bulging OEM's

    The ride is a million times better now the rears are not on the verge of death and the fronts are working correctly
    Last edited by Grafton; 05-29-2016 at 11:06 PM.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  27. #57
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    I'm glad I could help! I still can't believe how bad the old struts were, pretty scary, eh?
    '11 Lexus CT200h - Feb. 2024-Present
    '12 Toyota Aqua - AKA Prius C, JDM city runabout. Sold. Apr. 2023-Feb. 2024
    '09 Toyota Crown Hybrid - JDM executive missile. Sold. Oct. 2019-Feb. 2024
    '00 Toyota Vitz Clavia - Sold. Mar. 2018-Jun. 2021
    '11 BMW 328i Xdrive - Sold. Nov. 2016-Apr. 2018
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  28. #58
    SLi Supporter Grafton's Avatar
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    Incredibly scary, and I had checked the drivers side about a month ago and it was still in the proper place and not that rusty.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  29. #59
    SLi Supporter Grafton's Avatar
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    Finally fixing another old issue with the STi, the passenger side projector wasn't putting out the right amount of light:


    So I bought a wrecked headlight and stripped it for parts


    pulled my headlight and began to repair it


    notice the missing gasket around the high beam


    that made the interior of the housing get wet when driving through heavy rain


    then the low beam would short out because the ballast was getting wet


    the cause of the low beam beam problem was the reflector was burnt


    even the chrome head light insert had heat marks



    It's all back together and working perfectly.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

  30. #60
    SLi Supporter Grafton's Avatar
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    10000 Experience PointsO.G.
    Attempted to resolve the hot air intake on the STi, the first idea was an "intake box"

    closed up the gap between the spt heat shield and the intake piping


    added brackets for the lid


    top of the box


    It didn't work very well while I wasn't seeing the 185 F intake temp while in traffic I was seeing 150+ F and it would take forever to cool down after the car got moving and would still be ~15-20 F above ambient temps when ever the temp did come down.

    I got to looking at true CAI's decided I could make the SPT into a true CAI

    Grabbed a 60° 2.75" silicone elbow and a 45° 2.75" piece of inter-cooler piping and done





    It works much better the temps do climb while sitting in traffic but the highest it's went has been 130, and it drops quickly once the car is moving. Cruising I'm seeing within 4-7 of ambient.

    Logged for closed loop MAF scaling and the max correction was 2.2% from the OEM scale. I'm waiting on a wide band to scale open loop.
    2007 Impreza WRX STi
    2012 Impreza 2.0i Premium CVT
    Sold 1997 Legacy L Sedan, 2.5L 12:1 Compression Hybrid, The 'Lego'
    RIP - 2005 LL Bean Outback, The 'Bean' & 1999 Impreza Outback Sport

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