1-3-2-4's 97 Outback possible ej22e turbo project

[1-3-2-4]

Flywheel just came in it's 21 Lb

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2470-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2471-1.jpg

[1-3-2-4]

new slave cylinder along with intake manifold gaskets and valve cover gaskets

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2495-1.jpg

[1-3-2-4]

I guess I got everything.. starting off the week with two days of rain.. but who cares if you get wet..


http://img51.imageshack.us/img51/9012/dsc2505.jpg (http://imageshack.us/photo/my-images/51/dsc2505.jpg/)

Uploaded with ImageShack.us (http://imageshack.us)

New OEM T-stat

https://sl-i.net/FORUM/images/imported/2011/08/IMAG06751-1.jpg

oil pump O-ring
https://sl-i.net/FORUM/images/imported/2011/08/IMAG06771-1.jpg

[1-3-2-4]

Pulled the motor to do the HG's

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2581-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2582-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2585-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2592-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2601-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2603-1.jpg

clutch was starting to slip like crazy

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2610-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2611-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2616-1.jpg

[1-3-2-4]

some pictures.. just chilling getting one head off was enough work.. so I put the new flywheel on and replace that foam stuff since mine was gone.

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0730-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/IMAG0731-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/IMAG0732-1.jpg

So I did the oil pump.. I still need to drain my oil.. not much in the pan maybe about 3 qts really due for an oil change.

the screws on the back of the pump.. only two I took out to put thread locker blue on them the others I was unable to unscrew them so I figured they wont be coming undone anytime soon.

Old t-stat

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2620-1.jpg

All cleaned up with purple Power

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0735-1.jpg

Drivers head gasket

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2631-1.jpg

pistons after removed head

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2622-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2625-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2643-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2644-1.jpg

fork

https://sl-i.net/FORUM/images/imported/2011/08/IMAG07381-1.jpg


https://sl-i.net/FORUM/images/imported/2011/08/IMAG0736-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0734-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/IMAG07351-1.jpg

cleaning the bellhousing..

before:

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2582-1.jpg

After:

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0746-1.jpg

[Cervantes]

extremely impressive, i hope to be able to get this deep in the engine one day.

[1-3-2-4]

This is my first time.. all I can say is make sure you label everything! lol I have my parts in a ziplock bags.

Friday I'm going to go get the heads resurfaced I forgot to show the cleaning of pistons 2 & 4 but they look better then the above shots

the picture above where the head is laying flat on the tarp my lifters fell out so I gotta figure out what is what.. but the good thing is before all that happened I was only out of spec on like 3 and most of them were exhaust valves. the lowest was like 0.18mm from the idea 0.25 mm

[1-3-2-4]

Forgot to show the cleaned pistons yesterday #4 piston was pretty built up on carbon.

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0769-1.jpg

[Huffer]

You're doing great for a first timer!

[1-3-2-4]

a little nervous for sure only mistake I made so far was forgetting that the valve lifters will fall out and when I picked up the drivers head off the tarp they all got mixed :(

my guess is the only way to figure out what is what (I wrote the specs down before I took it apart) is to put everything back together and move each of them over to figure out which came from what..

Having said that the drivers side was worst then the passenger side as far as valve clearance goes.

[1-3-2-4]

Oh man got the passenger head off now in short block mode :grin:

Anyways the passenger side was way bad as far as failed headgaskets it left it's mark on the head where it did not make a good seal.

from the look of the gaskets they seem to be factory and this is the first change.. As far as the timing belt as you will see I can't say for sure if the Timing belt has ever been changed as well.. my car has 217k but it's odd this Subaru belt has the arrows but no line marks unless they wore away..

I got the passenger lifters out without any falling (yay) each in it's own little bag.. now as soon as I get the shims out I will check with the mic.

Now for the exhaust studs.. is it possible to get the nut off that backed out the whole stud from the head? I would rather not buy new stuff since a nut was like $5 or so from the dealer last time I looked.

cleaned the inside of the valve covers and put the new gasket on the covers.. also scrubbed down the intake manifold so it's cleaner then it was before.

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0781-1.jpg

cleaned the oil cap!

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0780-1.jpg

old Subaru belt

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0782-1.jpg

Passenger HG
https://sl-i.net/FORUM/images/imported/2011/08/IMAG0773-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0771-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0776-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2680-1.jpg

Yes I know I have surface rust which happened by mistake

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0770-1.jpg

I have a grill now :D

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0764-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/IMAG0783-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2684-1.jpg


Dirty

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2683-1.jpg

Clean

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2686-1.jpg

as for the IAC it's easier to take the top off because the shutter or whatever it's called wont move when spraying because it's held by a magnet by the way it's controlled.. So with it removed I'm able to move it about while spraying

Anyways hope the head bolts go in far easier then it was to take them out..

[1982gl4]

a little nervous for sure only mistake I made so far was forgetting that the valve lifters will fall out and when I picked up the drivers head off the tarp they all got mixed :(
.
I hate it when that happens, I only made that mistake once, that was enough for me to learn... Good progress so far though, grill looks great as well :smt023

[1-3-2-4]

haha yeah enough for me to not do it again too.. I did bag up the passenger side in each bag and about to use the micrometer on them in a few after I eat lol.. I been working on the car without food!

here is a time lapse from the first day


http://www.youtube.com/watch?v=kQyUpXLsOdM

[1-3-2-4]

Got the heads resurfaced and it was my fault really.. as I was driving I had this gut feeling that I should check my heads to make sure the lifters were in.. However I got halfway to Bridgeport and the guy calls me to tell me he forgot to put them back in.. so lucky for me I did not make it all the way home..

Anyways pictures!

damn only loosely put the passenger head on before it started storming like crazy.. it really was not the storm that stopped me but it was pouring rain like mad and I'm under a tarp lol

I've seen so many people get confused so here is a guide

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2695-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2696-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0812-1.jpg
https://sl-i.net/FORUM/images/imported/2011/08/DSC_2691-1.jpg

cleaned the TB cover yesterday

https://sl-i.net/FORUM/images/imported/2011/08/DSC_2690-1.jpg

[1-3-2-4]

Job is all done..

Here is the first start of the car after checking to make sure everything is connected.

I had water in the coil pack plugs since I had the hood open during a thunderstorm (working on the car)

after I blew it out it was fine.. also I'm missing a nut for the exhaust stud.

http://www.youtube.com/watch?v=hx7Ecy6_BJ0

[Huffer]

Well done!

[Reason]

What up with the weird idle and engine chatter when the throttle is pulled?

[1-3-2-4]

Thanks!

Now I gotta go find a nut that will fit I think it's M 10 x 1.25

Reason the coil pack is wet along with everything else I had the hood up for an hour during a thunderstorm while I was working on the car it idles fine now that I got the water out of the spark plug connections on the coil.

[1-3-2-4]

Replaced the slave cylinder and put a speed bleeder on it

old fluid that came out was NASTY

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0850-1.jpg

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0848-1.jpg

Making sure it's clear

https://sl-i.net/FORUM/images/imported/2011/08/IMAG0851-1.jpg

[1-3-2-4]

Waiting for the oxygen sensor to arrive and need to charge the AC system and replace the valve cores.

[1-3-2-4]

Not much has changed i did order some plug wires about a month ago because the wire was shot big time.. and part of the tip of the plug wire that snaps onto the sparkplug broke off and stuck on the spark plug.. it was a pain to get off (took me 6 hours) in the end and when it was raining I finally made a tool (sharp pointed hanger) and spearheaded the rubber boot to pull it out.

Anyways after I replaced the wires the car was fine since it was grounding out on the block.


next up is the transmission replacement As soon after I'm done with my headlights they will be going in.. I've did the right one so far which I still haven't fully checked it out yet... but went with the full blackout.. thinking about a little paint to hide the projector body as well not 100% sure on that.

https://sl-i.net/FORUM/images/imported/2012/01/DSC_3333-1.jpg

[1-3-2-4]

Well a little update since it's been awhile

Anyways my transmission finally took a dump

https://sl-i.net/FORUM/images/imported/2012/05/IMAG1057-1.jpg

long story short I suspect the input shaft bearing pins fell down into the front diff area and punched a hole in the tranny case which leaked out all my fluid I was about a mile from the house getting gas around 4:10 AM and so I limped back home under 20 MPH, I noticed any turns you make the transmission would bind up pretty hard almost to a full stop.

So I picked up a transmission from a 98 Forester yesterday with 86K on it, I plan on cleaning the case up before I put it in along with new shifter bushings and all. The transmission dry was not as heavy as i thought.. I'm only 125 lbs so lifting it was not so bad.

https://sl-i.net/FORUM/images/imported/2012/05/IMAG1082-1.jpg

[1-3-2-4]

Did a little cleaning, debating if I should change the axle seals and the rear oil shifter shaft oil seal, I was also going to paint the rear transfer tail cap and the top access plate just since it's out.

https://sl-i.net/FORUM/images/imported/2012/05/IMAG1103-1.jpg

https://sl-i.net/FORUM/images/imported/2012/05/IMAG11071-1.jpg
https://sl-i.net/FORUM/images/imported/2012/05/IMAG1109-1.jpg
https://sl-i.net/FORUM/images/imported/2012/05/IMAG1104-1.jpg

[Reason]

It's out, why wouldn't you change the seals?

[1-3-2-4]

because it only has 86K on it?

[1-3-2-4]

did a little painting and powder coating yesterday

A before shot

https://sl-i.net/FORUM/images/imported/2012/05/IMAG1116-1.jpg

After

https://sl-i.net/FORUM/images/imported/2012/05/IMAG1147-1.jpg

[anothernord]

Change the seals. You'll kick yourself later on when they leak on the car.

[1-3-2-4]

at 86K miles on it?

[Reason]

because it only has 86K on it?

Yea so,change the seals so it can go another 86k without leaking.

[Wagonista]

Yeah. I regret not doing my rear main seal when I had my tranny out. It wasn't leaking at the time... But it started to shortly after.

edit: Woah, 97s have hydraulic clutches? Lucky. I have a cable clutch on my 96.

[1-3-2-4]

Yeah I kinda think 97 was a transition year because my service manual for 97 has diagrams for both cable and hydraulic.. I love it No more snapped cable clutches I did that twice on my old Legacy one which left me stranded in NJ.. Man if it snapped on the GWB bridge It would of been a stressful time with stop and go traffic for like 10 miles....

it's nice not having to buy a qt of oil every Friday now.

[mike-tracy]

The 5mt EJ25's always came with hydraulic clutches in the states. A 97 tranny from an ej22 would be cable, hence the directions for both.

My 1991 came with a hydraulic setup stock. ;)

[1-3-2-4]

Thanks for clearing that up never knew that one.

[Grafton]

grab a TIC upgraded shift linkage while your in there, replaceable bushings and no more shifter slop FTW

[1-3-2-4]

Did some long overdue work like doing the rotors all around including the pads and finally put my JDM headlight sin with retrofitted turn signals and FX-R projectors.. The rotors were scary thin! Also put my auto diming rear view mirror up the day before which is nice
https://sl-i.net/FORUM/images/imported/2012/08/DSC00510-1.jpg



https://sl-i.net/FORUM/images/imported/2012/08/IMAG0167-1.jpg
https://sl-i.net/FORUM/images/imported/2012/08/IMAG0168-1.jpg

replacement caliper for the passenger front since the pistons wont retract.. ended up powder coating the new one.. will do the rest when I have more time.

https://sl-i.net/FORUM/images/imported/2012/08/IMAG0153-1.jpg

https://sl-i.net/FORUM/images/imported/2012/08/IMAG0171-1.jpg
https://sl-i.net/FORUM/images/imported/2012/08/IMAG0173-1.jpg

[1-3-2-4]

well looks like my motor might be done for since the valves got bent do to intake and exhaust valves slipped about 11 teeth when I had to stop hard without clutching in due to a jaywalker.. Lost all power but it will run but not well at all.

Anyways I'm thinking about doing a ej22 with ej25d heads running that until next year around may/April then start the turbo project.. No rush and I will just get the parts in the meantime, for the small stuff I'm looking at..

TD04 turbo
2007 wrx intercooler
2007 wrx downpipe (not sure if this will totally work)
wrx headers with uppipe
various hoses and oil feed lines