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Old 06-14-2007, 04:47 AM   #26
clsmooth
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Fuel pressure regulator is installed.

Put it in the place where that stupid FMU was. I'll relocated it after I switch alarms and relocate the siren
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Old 06-14-2007, 04:48 AM   #27
clsmooth
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Passenger side injectors installed :P

Ran outta time before work to put the other side in. Wasn't that hard, just movin a bunch of stuff outta the way first. Other side looks like more stuff in the way...
Hardest part was figuring out how the "special seals" I ordered from subaruwrxparts.com to adapt these injectors into my engine. Turns out they're nothing more then 8 RS top injector seals *shakes head* that you just mash on each end of em.

Last edited by clsmooth; 06-14-2007 at 04:55 AM.
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Old 06-14-2007, 04:49 AM   #28
clsmooth
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Interesting difference.

One question I had, what's that green nozzle thing added onto the stock injector? Does the stock injector spray that poorly?
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Old 06-15-2007, 11:47 PM   #29
clsmooth
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Special seals my a$$. They're so stiff, that the act of getting them over the lip and into the groove on the injector breaks them. I get to take everything apart all over again to change them with factory ones...
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Old 06-23-2007, 03:10 AM   #30
clsmooth
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Fuel pump's in, as is the other side of the injectors. Picked up a new air and fuel filter while I was at it. Car's ready for a base tune now.
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Old 06-23-2007, 03:21 AM   #31
semaj
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Nice work Get that thing back on the road!
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Old 06-24-2007, 02:39 AM   #32
kgb
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99 manifold man - should have gone for that and tap out the MAP sensor on it (99 used MAF). The stupid injector air assist on MY00/01 is what made it a pain in the arse to install any non-stock injectors. They used to make some injector adaptors for the MY00 until they figure out they could just use a whole bunch of right-sized O-rings. The debate for me when I get around to upgrade the fuel supply is 3 fold: STi/WRX or even bigger injectors (not necessarily good thing for idling or part-throttle drivability), Parallel fuel rails (seems to be important if your ECU can't do sequential which mine doesn't - you don't have that problem since you're running a piggy back eManage), FPR upgraded with SVX FPR or RRFPR (with RRFPR I can get away with just the WRX injectors instead of bigger ones because it delays hitting the duty cycle limit). Well, with me not working on that part of the car myself, I know for fact that it's a beotch to yank those fuel rails so good job
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Old 06-25-2007, 03:57 AM   #33
clsmooth
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Thanks for the heads up! Ya, not "special" about those seals. Almost forget, I need gaskets for a few things...
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Old 07-10-2007, 02:40 AM   #34
clsmooth
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Charged up the battery Friday night and got the car idling in the driveway! It was at a perfect 14.7 AFR, but at 20 psi of fuel pressure, cause I hadn't adjusted the regulator yet.

Let the car warmup, and started to increase fuel pressue, but I had to stop at 30 psi, cause AFR dropped down to 10. Even after playing with the eManage and cutting down the fuel by 70***37;, the best we were able to get was 10.4.

I reached the limit of the eManage and picked up a Link+ system that should do the trick.
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Old 07-10-2007, 06:13 PM   #35
A-Dev
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link+ FTW!
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Old 07-20-2007, 04:18 AM   #36
clsmooth
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I did a few things to the car the car's still off the road. I'm waiting for my Link+ system from speed_freak27 which is in Mississauga as of today.

Picked up the digital compass/air temp gauge from veightkiller a while back, and made an order from subaruwrxparts.com for its housing and a few other things while I was at it.


Also ordered new floor mats and shift boot as mine were starting to fall apart.


Also took advantage of the nice weather and recleared the hood in the backyard.
Before


After


Not bad for a backyard job. It's good enough for now although a few bugs stuck to the clear while it was drying... oh well, adds to the 'rally effect' I suppose.
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Old 07-20-2007, 04:23 AM   #37
Spy
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looks great, i want da turboz!
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Old 07-21-2007, 08:21 PM   #38
clsmooth
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Picked up the Link+ yesterday, everything appears in order, though some wiring just needs to be cleaned up in the adapter harness.
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Old 07-21-2007, 09:04 PM   #39
fujiwara_yingyu
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I like the bumper lip. Where did you get that? BC AUto design?
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Old 08-16-2007, 04:18 AM   #40
clsmooth
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Quote:
Originally Posted by fujiwara_yingyu View Post
I like the bumper lip. Where did you get that? BC AUto design?
Yup, BC Auto Design over in ON. (Markham, ON?)
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Old 08-16-2007, 04:19 AM   #41
clsmooth
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Got the car running and idling very nicely on the Link+ from speed_freak27. Everything works as promised!

Got it idling at a nice 700 rpm or so at 14.7 afr... then ran outta gas LOL Compass/gauge pack from veightkiller also works as promised! Just needs to be calibrated.
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Old 08-16-2007, 03:00 PM   #42
kgb
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Slightly OT - how hard was it to yank the gauge housing and the vents? I have the blue painted ones that matches your car *ahem*
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Old 08-17-2007, 04:54 PM   #43
clsmooth
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Quote:
Originally Posted by kgb View Post
Slightly OT - how hard was it to yank the gauge housing and the vents? I have the blue painted ones that matches your car *ahem*
The stock vent/dash box felt like I was about to break it taking it out but it came out cleanly. The new, top gauge half bolts in, and the new, lower vents part snapped in like a glove.
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Old 09-07-2007, 05:49 AM   #44
clsmooth
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To get the car through the new AirCare test of 98+ vehicles, I had to convert back to the stock injectors and ECU. With the car not boosting right now, now's the perfect time.

So I woke today and started workin on my car...

Did the injectors first cause they take more time. Manage to swap the originals back in, but not without dropping one between the engine and cross member and fishing it back out. With the exception of piping, the car was brought back to stock. In theory it should run, and sure enough it started right away and idled great!

Decided to get 2 days of insurance put on it and went down to Superstore down the hill from my house. Came back, stuck up the papers and pulled the car outta the garage for the first time in 8 months. Decided to take it easy at first to make sure everything was working. Putted down the alley, down the hill, all the way to Superstore. Couldn't go even if I wanted to cause of traffic. Get to the bottom of Rupert to turn right on Granville, give it gas and it just bogs and nearly stalls. I'm like, WTH?

Pull into the Superstore parking lot and try and rev the engine and it won't go past 2 000 rpm. Call a friend who says it sounds like it's really rich, and I might not have my FPR adjusted properly. I didn't have anything on me to adjust it, so... back up the hill I tried to go. Shook my way up Rupert at a speed slower then walking and the zig-zagged my way back up to my house. No engine light to whole time, just shook and moaned as if it were possesed.

Got it in the garage and started playing with the FPR. Any extreme didn't make a difference. Call back my friend who suggests to check a few things while he makes his way over.

Check one plug, black as midnight. Check all plugs, all black. My brother suggested to check the MAP. Found a few vague posts that suggested unplugging the first O2. Only thing I got from doing all that was an engine light. Thought the injectors might be sticky, but bros said I wouldn't be idling smoothly.

Friend comes by and I show him what the car does while he happens to be walking around it. He noticed there's next to no exhaust coming out the muffler; my cats might be clogged. (Yes, plural, previous owner couldn't pass AirCare, so installed 2 in-line cats.) Good thing he walked around though cause it's not something I would've been able to diagnose by myself.

Held a temp probe and by touch notice the front cat was quite hotter. The first cat was connected to the downpipe using a U-clamp. The 1st and 2nd cat were connected using another U-clamp, and the 2nd cat was bolted normally to the cat-back using spring bolts.

We agree to take out both cats as one. Ended up braking the front U-clamp off and the disconnected the back cat. Looked back up into the 2nd cat and the honeycomb looked fine. Couldn't get the 1st cat off the downpipe due to the crimp left by the U-clamp. Using a drill and a grinding disk, made a slit on one side of the pipe to relieve pressure off the crimp. After some pounding on the flange, both cats came out. Fired it up quickly with them out and it revved up to 5 000. I think we found the problem...

Looked down into the first cat to reveal hand-sized chunks of honey comb all over in the cat! Turned it down and these rocks of honey comb rolled out. Some of the element of the first cat melted to the element of the 2nd, so... both cats got hollowed out using a foot long masonary drill bit!

Put everything back together and fired up the car, and for the first time, sounded like a Subaru with an exhaust, ready to rally! Friend said I owed him a Big Mac so we went for a drive.

Wondered if the wastegate was burnt out as much as the cat, so under controlled conditions, gave it some gas to see if it'd boost and it snapped up to 3 psi before I could react and let go. Wastegate doesn't appear burnt but will be replaced as it's rusted to hell. But thankfully my worst fear in this whole project wasn't the case... THE TURBO'S NOT BLOWN! THE TURBO'S NOT BLOWN!!!!!!! hahaha

Going to have it put up on a hoist at my bros. work to fill a few pin holes found in the exhaust before attempting AirCare.
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Old 09-07-2007, 01:06 PM   #45
kgb
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I guess you will make it boost nothing during AirCare? I'm going to have the same problem again come March
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Old 09-07-2007, 05:24 PM   #46
fukamoto
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Funny how the littilest problems can cause the largest headaches. I remember my car couldn't start for 3 days. Low and behold, pull out the spark plugs and they were a write-off. Put on new ones and it fired up like a champ.

Dirty cat. Meow. That woulda been my last guess
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Old 09-07-2007, 11:49 PM   #47
Penphoe
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[anecdote]
I remember when I was in highschool, my grade 12 english teacher was laughing at how much Aircare was a joke. His old car, had an rusted out exhaust. Anyway, there were holes in the exhaust system. He said that these holes allowed him to pass airscare. Why? Because as the exhaust went through the piping, it would draw "clean" air through the holes which diluted the exhaust mixture coming out at the end!

In any case, that's my anecdote.
[/anecdote]

Good luck getting it through Aircare! Glad to see another GC RS-T is still alive!

LaterZ!
Darren!!
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Old 09-08-2007, 01:18 AM   #48
dasnowman
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I guess that's why the 07-08 Suby's have an air pump/compressor to pump air into the exhaust to make it better for emmissions. Seams like a cheating way to get there but who cares. Global warming FTW right??
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Old 09-08-2007, 05:13 PM   #49
Joyride
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Project mode.. no kidding Looks like you're really researching/doing it right, saves lotsa time down the road.
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Old 09-09-2007, 12:42 PM   #50
clsmooth
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So Friday morning I wake up to head over to my bros shop in Abby the patch up the cats I couldn't get to fit back quite right. The slit I made left a 4 or 5 mm by 2 or 3 mm rectangular hole. I still can't go through AirCare with leaks and a drive out to Abby would certainly test that everything's working and build up enough data for AirCare.

It was the first "long" trip for the car in 8 months, so I took the Fraser Hwy on the way there, just in case. Ran great, though could smell some exhaust when at a red light. My throat was a lil dry by the time I got there. Put it up on the hoist and my bros was kinda enough to weld up the hole and double checked the whole exhaust for any leaks.

I asked if I'm ready for AirCare, but he wasn't sure (every car's different with its data collection), so he connected to his scan tool and all systems looked good. He said to go ahead and try AirCare cause I'm reading everything's fine.

I get to the AirCare in Abby (cause it's the only where I know where it is hehe) I got in and I'm asked to keep driving just past the dyno rollers. They unrolled a long cable with an OBD connector on it and I didn't have to hide in the booth cause they weren't driving it. No gas cap pressure test even, but they still held the mirror under the car to see if there's actually a cat and any leaks.

The turn on your ignition to see that your engine light comes on and works. They then turn it back off, connect, and actually start the car and have it idle while they're checking for codes. And probably to also make sure your engine light goes out when the car's running.

I look up at the monitor to see 'Linking to vehicle', look away at another car, look back, and the test is done and I passed! Passed AirCare without a cat! LOL (and a fooled secondary O2).



Oh ya... here's what's left of the insides of both my cats...

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