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Old 12-15-2021, 10:12 PM   #51
Bugeye115
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Started cleaning up the 2004 STi steering rack and pump I picked up last summer. The current WRX rack was leaking so I decided to upgrade.
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Old 12-15-2021, 11:37 PM   #52
Scooby South
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Awesome How did the suspension do??? Congrats on the engine.. you will notice the torque difference for sure ...Good to hear from ya

Bill
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Old 12-17-2021, 10:16 AM   #53
Bugeye115
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Quote:
Originally Posted by Scooby South View Post
Awesome How did the suspension do??? Congrats on the engine.. you will notice the torque difference for sure ...Good to hear from ya

Bill
Thank you! The car handles like a dream on the track, but I still have a lot to learn about suspension geometry and setting the right damping. The coilovers do make the car rough riding on city roads, but I don't drive it around town that often.

I'm excited to feel the extra torque down low. The 2L was definitely struggling on some of the uphill climbs at Hallet.

SJ
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Old 12-31-2021, 08:15 PM   #54
Bugeye115
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Sneak peak of what's to come!
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Old 01-07-2022, 09:33 PM   #55
Bugeye115
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Update #15

The EJ257 is ready to go back in the car. I decided to swap over the timing components from my Ej205 since they have less than 1000 miles on them. I went ahead and swapped the waterpump as well.

The ej257 had a gates timing kit on it and I have to say, the AISIN kit I had on the ej205 is of higher quality. I'm happy I decided to switch them out. I belive the AISIN kit number is TKF 004.

Next step is to get the car in the air and remove the old 5-speed and WRX steering column.

Until next time!

SJ
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Old 01-09-2022, 03:53 PM   #56
Bugeye115
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I started taking the 5-speed out of the WRX today. Went to drain the oil and this is what I found. I'm glad I decided to put a 6-speed in the car!
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Old 01-10-2022, 08:20 PM   #57
07imprezRS
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That’s a big chunk!
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Old 04-25-2022, 02:23 PM   #58
Bugeye115
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Update #16

It's been a while but I assure you I've been hard at work.

Since my last post, I've installed the new EJ257 and 6-speed transmission. The engine bolted right in of course. I did have to purchase a 6-speed transmission mount and Ver7 JDm STi driveshaft in order to make everything work with my R160.

I originally wanted to use my 5-speed clutch and flywheel since they only had 1k miles on them, but I soon ran into some issues. After installation, I started to experience a high pitch noise at idle and while driving. The noise went away once the pedal was engaged. After much research, it was determined that I needed a 6-speed clutch and flywheel set up. So I went with an ACT setup and Comp Lightweight flywheel.

I also installed a factory short shifter and iWire VSS controller since my 6-speed didn't come with the vehicle speed sensor on the transmission. The iWire kit utilizes ABS sensors to pick up the vehicle's speed. No calibration was needed. I highly recommend this kit if you're looking at a 6-speed swap. My transmission doesn't have DCCD so I didn't have to purchase their DCCD kit.

I also installed the iWire grounding kit, and DOMTuning Cylinder 4 cooling Mod while I had everything out.

The car is currently being tuned on 91. We will be heading to our local track, Hallet Racing Circuit, this weekend to test out the new setup. Stay tuned for an update!

Last edited by Bugeye115; 04-25-2022 at 02:29 PM.
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Old 04-25-2022, 02:59 PM   #59
Karlot
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so happy i found this thread. cant wait to see what the future holds for both the car and you on track as the driver. i'm slowly getting into tracking myself so this type of content is what i want to see for nasioc and iwsti.
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Old 04-26-2022, 09:56 AM   #60
Bugeye115
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Quote:
Originally Posted by Karlot View Post
so happy i found this thread. cant wait to see what the future holds for both the car and you on track as the driver. i'm slowly getting into tracking myself so this type of content is what i want to see for nasioc and iwsti.

Thanks for the kind words! I'll try and keep you apprised! I plan to attend at least 4 track days this year.
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Old 04-26-2022, 10:19 AM   #61
Karlot
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Quote:
Originally Posted by Bugeye115 View Post
Thanks for the kind words! I'll try and keep you apprised! I plan to attend at least 4 track days this year.
lol sounds good. I WISH i could get to 4 track days this year, i just got married, so i'm financially recovering from that currently, hoping to get to at least 1, but most of this year is setting the car up to be competitive for my local trackcross next year. hopefully they dont make any crazy rule changes lol.
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Old 05-02-2022, 03:57 PM   #62
Bugeye115
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Well... sad day. Everything started off great. Made it through three rounds of high-speed touring before a giant cloud of white smoke came out of the back of the car. Lost significant power coming out of a turn, looked back and there was a huge cloud of white smoke.

I just got home, but my initial thoughts are the turbo blew a seal. Everything else looks good except for the oil that is leaking out of the turbo. I also believe this caused the engine to knock... which is very noticeable at idle.

I'm not 100% sure the engine isn't gone. I am 100% the turbo is. DAM did go down to 14 when all this happened but there was no feedback knock or learning knock on my AP. There are also no check engine lights.

Sounds to me like more of a mechanical issue than tuning.

I'll be parking the car for a couple of weeks while I develop a plan. Any input is welcome!!
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Old 05-03-2022, 11:05 AM   #63
Karlot
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dang. i'm sorry to hear that. hopefully the engine is ok and it's just the turbo. Keep us posted on what it is
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Old 05-14-2022, 01:52 PM   #64
fonzinator
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Bummer! Loved seeing where you've taken this 2004 - hope you get it back on her feet soon.
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Old 05-24-2022, 11:29 AM   #65
Bugeye115
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Small update:

I have compression on cylinders 1-3, but nothing on cylinder 4. After posting in the tech threads on NASIOC, I have a couple of theories on what happened.

1. The turbo seals let go causing a large amount of oil to evacuate the crankcase and starved cylinder 4. This could have caused a ringland to break on cylinder 4.
2. Cylinder head for 2 and 4 could have burned up a valve causing no compression on cylinder 4.
3. A combination of the above.

This week, I will be pulling the engine to complete a leak-down test on the cylinder head for 2 and 4. Either way, I'm looking at a new turbo and some head work. A new shortblock is in question. If I need a new shortblock, I will go with the factory RA block as that is more suitable for my power needs.

I have started ordering some parts and will keep you all posted.

Thank you!
SJ
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Old 05-24-2022, 11:34 AM   #66
DrTrae
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Man, that sucks.. Hope it isn't hurt too bad. Although, forcing your hand on an RA block sounds pretty nice.
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Old 05-29-2022, 02:10 PM   #67
Bugeye115
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The engine is out

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Old 05-30-2022, 10:08 AM   #68
Bugeye115
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And now it's on the stand

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Old 05-30-2022, 10:20 AM   #69
eldrego
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Nice work
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Old 05-31-2022, 10:02 PM   #70
Bugeye115
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Found the culprit...

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Old 06-01-2022, 01:04 AM   #71
yamahaSHO
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Do you have pictures of the rest of the cylinders and spark plugs?
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Old 06-01-2022, 07:20 AM   #72
DrTrae
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Quote:
Originally Posted by Bugeye115 View Post
Found the culprit...
Dang... That sucks man, I'm sorry.
Time for the RA block then?
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Old 06-02-2022, 10:51 AM   #73
Bugeye115
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Quote:
Originally Posted by DrTrae View Post
Dang... That sucks man, I'm sorry.
Time for the RA block then?
I'm still weighing my options. At this point I'm leaning towards at least a stage 1, maybe a stage 2, engine so this doesn't happen again.
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Old 06-02-2022, 05:14 PM   #74
motorbykemike
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check your messages
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Old 06-24-2022, 11:35 AM   #75
Bugeye115
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Small update!

I dropped off the ej205 at my local Subaru shop for their stage 2 package! The package includes a new OEM crank, Manley H Beam rods, Manely forged pistons and KING Bearings.

I went back and forth on whether to use the ej257 or the ej205. As many of you know, I could not use the AVCS on the ej257 heads. After speaking with numerous NASIOC members, I'm sure this was part of the reason we melted cylinder 4. Therefore, I have decided to build the ej205.

I will also be refreshing the ej205 heads.

Stay tuned!
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