XRAYSPECS - 2002 - BE - L - Upgrade Everything

**xrayspecs** · 04-29-2024, 09:25 PM

Well went to get lunch on saturday, nice day out and while waiting in the drive through noticed "im in danger"

Temps came right back down as soon as i kicked the heat on max and stayed average while the car was moving, so took it easy on the way home.

Let it all cool down then got underneath too see if something was leaking, water pump/radiator/hose/heads/etc. to find it all looked okay no build up/crust that would suggest a leak, except the rad cap looked like the heat cycling from the road trip killed it.

One radiator cap later from the lps and looks like the problem is solved. hopefully no need for more work anytime soon.

cars are stupid.

**Muse** · 05-01-2024, 05:34 PM

I think that's what caused my 3.0 to pop it's head gasket. Got way too hot on a long drive and it's never been right since. But you seem to have caught it far sooner than I did, so here's wishing you luck.

**xrayspecs** · 05-02-2024, 11:56 PM

One week of freeway driving in the 80s and 90's and the gauge never moves above middle so I think I got lucky. TBH the cars one email from copart with a donor away from getting a spicy powerplant.

**xrayspecs** · 03-20-2025, 01:04 AM

It has been a while, had a few maintenance items that needed to be addressed.

Took another road trip out of town and had some warmer temps on the gauge in the middle of the 115 desert.. worried about a possible head gasket issue.

Used this to check for leaks.... showed that everything is still good. guessing the water pump is getting tired and old and due for replacement.

Started to get bad pad knock and noises really bad really fast, quick check of the car found passenger side bearing was on its way out fast.

Got new bearings.

When doing the work discovered the hub was also toast.

New Hub and back together, also looked around the back end and found this bushing on its way out that was the reason the rear end felt looser than it should.

Didnt drive the car much while getting parts and other items.

Hit 200k miles.

Did take some time to clean up the headlights as they were hazing bad.

[

Tires were also due since this summer. finally got some new Conti's.

Also replaced the worn bushings as they were the main suspect in causing the acerated wear on the rears this summer.

Went with the non eccentric outer to see if it helps this issue since i have the adjustable arms.

Also added a new dead pedal from Kart boy.

**ryu_haneda** · 04-02-2025, 07:55 PM

When I drove my old '98 Legacy GT, the water pump eventually came up for service. I'm nowhere near this level of do-it-yourself, so I took it to get replaced. Parts and labor were not cheap, but it got done.

**xrayspecs** · 04-03-2025, 12:39 PM

Yeah i havent got to it quite yet, i still need to pick up the fluids, a new tstat and a coolant plug since the factory oem cooler/heater is starting to leak and needs to come off.

Its time for a new belt and idlers anyways so might as well do it all at once.

**xrayspecs** · 09-15-2025, 06:37 PM

Decided to take the car down for substantial work this summer, first spring day it went over 80 deg the car was getting warm and wouldn't cool down when sitting at a light confirming that the head gaskets do indeed need to be replaced. also meant the parts pile I have could be put on the car at the same time.

Working out of a garage with A/C is amazing.

Made quick work of getting it stripped down to a shortblock.

Headgaskets are toast after all this time and milage this was the number 4 cylinder and was one of the worst.

Quick work to get the rest of the block stripped and ready for work.

Heads and block deck needed to be cleaned up before rebuild.

Took my time with glass blocks and plate i have and lapped the heads and block to clean up all the defects. Lots of patients and wd-40 to lubricate and clean.

Also installed a new Aisin Timing kit and water pump and OE t-stat on the block.

Removed the OEM water/oil cooler/heater loop on the oil filter stack. it always leaked and made it a pain to change the filter with the Borla headers. kept all the parts but used parts from the scrapped engine (tstat housing/filter tube) and a new from the dealer block plug to delete.

Clutch and flywheel also needed to be done (had cold morning chatter bad) so had the spare flywheel turned and got another Exedy oem kit. took the time with the flywheel off to clean all the clutch material off the back of the block.

Also took the time since everything was apart to fix the notchy shifter feel on the transmission, the replacement pitch stop made a huge difference in slop and shift feel so got a replacement OEM ujoint.

Installed the STI OEM short shifter as well. STI short shifter on the right oem on the left.

STI pivot distance.

vs OEM.

When installing I found out i had overlooked which years legacy the one i bought would fit and bought one off someone on here for a 05+ legacy/Impreza. nothing a little problem solving couldnt fix. cut this much off the back of the shifter, if you dont itll run into the chassis and bind the whole shift assembly up. cut it off and everything slid together how it should and works with no binding or issues for the last two months with the kartboy bushings. also replaced the rubber bushings in the ujoint with a Torque Solutions Solid shifter bushings.

While looking over the front end, noticed play in the passenger side wheel bearing again. after looking into it, the outer wheel bearing seal was not staying seated in the spindle and was spinning on the wrong surface. So bought all new bearings, seals and hub again. this time also added some Loctite 648 on the outside to retain the seal in place so I don't have this problem again and put it all back together.
[img]https://live.staticflickr.com/65535/54787334876_7cbc061dbf_c.jpg[/img

Which is great because! adding some new brakes to the front of the car. 04' STI street brake kit from Powerstop. Price on these was too good to pass up for fully built calipers, pins, springs, pads and rotors. For good measure also replaced the front soft hoses with new. Also got 4 new '04 STI front caliper bolts from the dealer as the Brembo's take a different bolt than the OEM calipers and i have trust issues.

Now to put it all back together. Went with Mahle for the gasket kit.

Got some help too putting it all back together. His first help with a rebuild.

All new timing triple checked timing and set the lash on the valves to oem.

Almost there.

New filter too as this one needs to go.

All burped and ready to rock. The car drives with so much more power than it had before!

Lastly a wash and wax! it needs a glass out respray but i dont have the time or space to do it proper right now so just driving and enjoying it.