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Thread: rkrenicki's 1992 Subaru Sambar SDX - 2021-05-07 - Stirring from slumber...

  1. #151
    Administrator rkrenicki's Avatar
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    It has been several months, and in the meantime I have largely been doing some maintenance tasks. The distributor had a failing oil seal, so the cap was accumulating oil. Subaru does not sell the seal on its own, so I ended up replacing the entire distributor base. I also replaced the valve cover bolts to spruce it up a little bit since they were only $1 each.
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    Last night, I decided to tackle the wiring situation. It has a super simple wiring harness, and I have probably doubled the amount of wiring behind the dash with things like the auxiliary lighting, LED Headlights, power windows, and radio. Since all of these things were done at different times, it just became an intermingled mess of wires, relays, fuses, and random connectors. I also never really cleaned behind the dash, it is still covered in JDM dirt. Here is what it looked like just after the dash coming off:
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    I am working systematically across the dash, relocating relays and zip-tying all of the cables so that there will be none exposed, and cleaning up all of the dirt while I am in there.

    I have also found that Subaru Japan has been discontinuing parts left and right as of late.. I have been busy sourcing and acquiring spare parts to keep this truck on the road for another 25 years. I now have several boxes full of hoses, gaskets, bearings, bushings, etc.. My own little parts store in my garage just to keep it going. In my research, there is a surprising number of mechanical parts shared with the DL/GL platform and the Justy. I bought a NOS steering universal joint from Subaru here in the US that was made back in 1995. This particular part has been discontinued in Japan for quite a while and is not available in Japan or Europe, but it has been sitting quietly in a US warehouse for 24 years waiting for me to put it on my shelf.
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  2. #152
    t3h ub3r m3mber dodik's Avatar
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    Just saw one of these this morning by my son's school. They are very tiny.
    Good luck on the wiring, its a finicky job but once its done its easy to fix any issues that may arise in the future. You of all people probably know this the most that if its messy back there you will get gremlins and after a few years you tend to forget what goes where.
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  3. #153
    Administrator rkrenicki's Avatar
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    Quote Originally Posted by dodik View Post
    Just saw one of these this morning by my son's school. They are very tiny.
    Good luck on the wiring, its a finicky job but once its done its easy to fix any issues that may arise in the future. You of all people probably know this the most that if its messy back there you will get gremlins and after a few years you tend to forget what goes where.
    Yep, I am fixing those gremlins now, actually. This will also give me a chance to finish my gauge setup and leave provisions for the additional lighting that I have not yet installed, but still allow me to remove the dash without cutting wires or zip-ties. My goal is to have 2 or 3 interconnects between the "bulkhead" and the dashboard, and no more. Fun fact, the stock interconnect between the two is just one connector with 10 wires.

  4. #154
    Administrator rkrenicki's Avatar
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    Wow, there are a lot of things that I neglected to post here.

    Here is a progress shot of the cleaning of wiring and dirt:
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    I moved the gauges to be on the A-pillar instead of the dash. I ran the wires inside the pillar and used some Rivnuts to attach the meters.
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    The dash was very faded from many years of sitting in the Japanese sun.. I decided to try to fix it with a heat gun, and while not perfect.. it is quite a bit better.

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  5. #155
    Administrator rkrenicki's Avatar
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    I ended up replacing the mirrors with the larger Van style mirror, which has a second attachment point to support itself. I also installed new door handles and plastic inserts around the door handle, also from the Van.
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    Flash forward about a month, and I started buttoning the dashboard back up. I had to make some last second wiring adjustments because of various fitment issues, but this is largely how it ended up looking underneath.
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    All back together, and I finally hooked up my Defi Sports Display F that I had in the box for almost a full year.
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    Flash forward another month or so.. I finally had the bed sprayed with bedliner. This was something I was planning from day one, and I never got around to it.

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  6. #156
    Administrator rkrenicki's Avatar
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    And the last update, for now.

    After some trimming off the hinges and installing some new bolts and screws.. I have the powder coated sides back on, and the backrack back on.
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    I also found that the engine mount was torn, so I swapped that out.
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    And last but not least.. I ended up repainting the engine "hood". It has taken a bump or two in its life, and the paint was less than perfect. I am still waiting for the paint to fully cure before putting the plate back on, but it looks 10x better than before.
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  7. #157
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    If you bring "sammie" to WBM don't be surprised if your missing a window crank-one of my is broken
    Legacys are like potato chips-You can't stop at just one!

  8. #158
    Administrator rkrenicki's Avatar
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    There has not been a whole lot of changes since June. Sammie has been in hibernation for the winter since they started putting down salt in October, and he has been collecting empty boxes in the bed to be brought to recycling come the spring. I did change up the gauge setup a little bit though. I got rid of the Defi Sports Display F and replaced it with an Advance ZD. The only real function I used of the DSDF was the speedometer and perhaps the water temp.. both of which the ZD is more than capable of doing. The ZD is also much easier to read at a glance with its high-contrast OLED display. I also have the ability to place the display in more places since it uses the normal Defi mounting system. I haven't fully decided on its current location, but it will be somewhere in this vicinity.
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    Otherwise, Wicked Big Meet was pretty cool. We had a freak rain storm in the middle of the day, but it was pretty short and we all got back to normal pretty quickly.
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    I did end up taking home second place this year, but by far the highlight of the day was when Chris Atkinson was walking by, I offered for him to hop in.
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  9. #159
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    He looks right at home!
    Legacys are like potato chips-You can't stop at just one!

  10. #160
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    Yesterday was 3 years since Sammie arrived in the US. I am eagerly awaiting spring so he can stretch his tires again

    I also apparently need to update the photos in the first post! They are VERY out of date!

  11. #161
    Administrator rkrenicki's Avatar
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    I finally put all of the Subarus in a row today. Finding a time when all of them are home during the daylight is not the easiest thing in the world.

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  12. #162
    Administrator rkrenicki's Avatar
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    There have been no significant changes to Sammie since the gauge changes late last year.. but that is all about to change. I have all of the parts on hand for three big modifications, and work has started now that Sammie is in hibernation for the winter:

    First: OEM Oil Cooler. All of the Supercharged Sambars with automatic transmissions, and all of the Supercharged Akabou vehicles regardless of transmission type have a small water-cooled heat exchanger for the oil. It is similar to that on the EJ and EZ engines, just smaller. It does require changing out the Thermostat housing, and one of the long metal pipes heading up to the radiator to plumb it in, but it will be a good way to keep the oil temperatures down. I have only installed the heat exchanger itself so far, but the rest is coming soon.
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    Second: The 1998-2012 Supercharged Akabou engines had smaller, lighter, and forged pistons. The Akabou and JA vehicles from the same time period also had different "heavy duty" rings. I found a few people in Japan who have replaced their Pistons and Rings with these versions and report a slight compression increase (due to a different chamber shape), and a 20% fuel economy increase! In the meantime, here is a picture of a new piston next to the one that was damaged back in 2017.
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    Third: Many versions of the Sambar had Electric Power Steering available. I have all of the parts to add this to my truck, but I will need to figure out the wiring. Out of the 15 or so wires needed, one of them is not on my particular diagrams. My dash is currently removed and the parts are mounted, but no work will finish until I can figure out that last wire.
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  13. #163
    Administrator rkrenicki's Avatar
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    I pulled the bed off yesterday to give access for two of the projects. This is the first time I have pulled the bed since it was bedlined, I ended up needing to cut a little bit of the liner where it met the cab. I will have to figure out how to re-seal that when this goes all back together.

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  14. #164
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    Todays progress
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    All of the ancillaries and head are off. I still need to figure out how to remove the oil pan like this.. I may need to pull the CV first before I can get that out.

  15. #165
    Administrator rkrenicki's Avatar
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    I managed to get the pan off.. boy I sealed that on very well last time. With the pan off, the pistons came out and were replaced one by one. I weighed the old and new piston crowns, and the new ones are a little under 10% lighter (about 18 grams lighter each).
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    I installed all 4 pistons, and it looks pretty good. I need to get some new batteries for my torque wrench before I can start buttoning it up, but it is largely reassembly from here in.
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  16. #166
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    Reassembly continues: New 2002+ model MLS head gasket installed.
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    Head reattached
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    I also carefully spun the engine in various cam positions, and I am happy to report that the engine is still Non-Interference after all of these changes. I whipped on a new timing belt, even though the 3 year old one was just fine. Other than that, I am in mostly in a holding pattern until some items arrive from Japan. I decided to try a new vendor this time around, and they are being less than fast.

  17. #167
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    While doing some research over the last few days, I have discovered that the english translated service manual has a critical error when it comes to the head bolt torque. The torque pattern indicated is backwards (it shows the removal order), and also only lists the first of 5 steps to properly torque. If I had followed those directions, the bolts would have less than half of the torque specified in the Japanese manual. Luckily, I caught it early, and it is now properly torqued.

    The last items that I have been waiting for have finally arrived at my proxy. I just submitted the request to have them all shipped to me via DHL, so I hope to see them in the next week or so. I also have a small pile of metal brackets with various levels of surface rust, that I am going to drop off at the powder coater on Monday. I do not need them to be particularly flashy, just protected for the long term since they are no longer available new. I hope to have them all back in the next week or two as well.

    I did install the new coolant pipes the other day while I wait for everything to show up. There are some new brackets in my above order, so they are only temporarily held in with one of the old rusty brackets right now.
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  18. #168
    Administrator rkrenicki's Avatar
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    So, the truck is finally off the jack stands as of today. I took the opportunity to replace ALL of the fuel hoses, the last of which showed up this week. I also changed out the fuel filter.

    Everything is completely assembled, except I need a second set of hands to re-attach the bed. Once that is done, I can reconnect the last coolant line and I can refill the coolant system. I do still need to finish the power steering wiring and reinstall the dash.. but then it will be finally ready to move again!

    Oh, and Sammie is also undergoing a bit of a rebrand as well... more to come on that soon.

  19. #169
    Administrator rkrenicki's Avatar
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    Sammie went back outside for the first time in 6 months. I have not reinstalled any of the dash, and the bed is just sitting on top of the frame.. not bolted down in any way, nor are any of the sensors/relays/etc reattached to the bed... I just wanted to get the cooling system refilled and burped and one of the coolant pipes are attached to the bed.

    I let the engine get to full temperature to properly burp the system. The oil temperature is far more consistent now with the new oil cooler installed. I did not take it out for a drive at all, but the temp was staying closer to coolant temp the whole time.

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  20. #170
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    So, it turns out that I accidentally put old used coolant in. I realized it almost as soon as I finished burping the system when I saw little flecks of stuff in the funnelbucket. I ended up buying new stuff.. draining, refilling, and re-burping the system today.

    I also started to install the Subaru Dealer-installed option power window motors. They do stick out a bit, and it is right where my knee is.. but a big smooth bump is better than the hard edge of the manual winders.
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    Here is another shot with me in the seat with the door closed.
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    Since the cheap eBay aftermarket power window kit is coming out, that leaves me with some holes in the dash where the vents would be on the van... so I found a kit to actually add these vents. It is currently on its way from Japan right now, so my dash reinstall will have to wait until those show up. Besides, I have not yet finished the power steering wiring either.
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  21. #171
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    The vents arrived and have been installed.
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    I need to finish up the power steering wiring before I can put the dash back in.. the finish line is within sight!

  22. #172
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    I finished up the install of the Power Window motors. I still need to connect the two power connections and it will be all done.
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    I also sorted out some of the wiring for the power steering.. I still have 7 wires to connect, and that will also be complete.
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  23. #173
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    Power steering is now sorted. Two of the wires were only needed for diagnostics, so I decided to leave them out. That left only some power wires, engine speed, and vehicle speed. I have not moved Sammie yet, but turning the wheel at a dead stop is significantly easier, which was the whole point.
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    I need to sort out a few other small things like lubricating the heater dampers and mounting the passenger side relay block.. then the dash can go back on!

  24. #174
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    Got the dash in, and drove him around.
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    I forgot to slide one of the hose clamps back on up around the bleeder in the back, so it ended up being a little incontinent right on top of the engine. I repositioned the clamp and now can hold it.

    Now that it has the dash vents from a van, and the power steering... reconnecting the speedometer cable is a serious PITA.. even more so than it was before. I totally understand why you van guys can't figure it out. I ended up having to drop the Steering Computer and I had just enough room to get my arm up in there.

    The power steering will take a little getting used to. It is super light all of the time, it almost like playing a video game with a steering wheel, but making three point turns is quite a bit easier now.

    The vents are "alright". Not sure if they were worth the cost, but they are better than having holes in the dash.

    I lubed up the windows with some dry teflon, and they work great with the power window kit. Highly recommended if you can find a complete set

  25. #175
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    It took me about 4 1/2 years.. but I finally tinted the side windows. I went with a 42% Carbon Tint (same as the Forester), which combined with the glass gives me about a 37% VLT.

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  26. #176
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    It took me almost a year, but I finally found the cover for the power steering mechanics. I ended up having to buy another whole Power Steering setup (column, computer, wiring, etc) to get it, but I guess I now have some spares.
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    I also gambled on the frameside Tool Box for the 6th gen Sambar. Turns out that it bolted straight on with no modifications, and it works great!
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    Otherwise, Sammie underwent a bit of a rebrand as well. Since he has most of the special parts that would make him an Akabou delivery truck, and I already had all of the stickers on hand from another documentation project.. so I cleaned off all of the old decals and put on the bright red Akabou markings.
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  27. #177
    SLi Resident thenines''s Avatar
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    The decals make Sammy pop!
    Legacys are like potato chips-You can't stop at just one!

  28. #178
    Administrator rkrenicki's Avatar
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    Ive got a couple of updates! I found a few OEM bits that improve the truck a bit.

    First, The passenger seat gained a parcel shelf and a rudimentary cupholder starting in the middle of 1995, so I replaced the seat with one from a 1997 truck. It is the wrong color, but I am working on finding some replacement vinyl.
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    Second, The Akabou vehicles moved their passenger side mirror off the door and up to the fender to improve visibility on that side. It took me a long while, but I finally found one for sale that is the appropriate design for the early 5th gen models. It required that I installed some Rivnuts into the body for the mirror to attach, but that was not too hard. I did not remove the door mirror, instead I angled the fender mirror to show me further out. The fender that was included is in pretty rough shape, but I am using it for now until I can drill out some new holes in my original fender.
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  29. #179
    Administrator rkrenicki's Avatar
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    It has been a quiet year, mostly because the summer so was hot this year and the lack of AC in Sammie would make it unbearable to drive. He did get a few trips though, mostly to the dump and donating some appliances to Habitat for Humanity.. but he is back into hibernation for the winter again.

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