GROUNDED - Starting an EJ205 Rebuild - Page 4 - Subaru WRX Forum
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post #46 of 55 Old 09-11-2014, 05:56 PM Thread Starter
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Yes John, I'm interested if it's designed for an '04 WRX as well.

I'm hoping I'll get a fair deal from you, because it'll need to be shipped to Toronto, Canada.

Will send you a PM.

Cheers,
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post #47 of 55 Old 09-21-2014, 07:37 PM Thread Starter
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blown WRX motor teardown.

Found a spun bearing on cylinder 1 and an exterior head gasket leak that weakened a head bolt. That bolt snapped upon disassembly.

One rod is scrap and the crank throw needs to be polished for an over-sized bearing, the rest seems salvageable as a spare.
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post #48 of 55 Old 09-21-2014, 10:49 PM Thread Starter
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We also found carbon deposits in the intakes, which is likely from oil vapor getting into the intake from blowby due to age.


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post #49 of 55 Old 09-22-2014, 11:32 AM
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Nothing like a leaky valve cover seal to make a engine block all messy with oil. :-P
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post #50 of 55 Old 09-22-2014, 01:26 PM Thread Starter
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There were a few 'age' issues with this old motor, so it was due for a rebuild.

In hindsight I would advise myself to go with a pro-active rebuild, rather than running this one to failure.

The STi rod upgrade cost me 100 $CAN and the new OEM crank was 550 $CAN plus tax. In addition the tow cost 240 $CAN and I'll estimate that the timing of the motor failure in the middle of rebuild season meant another month delay to get it back on the road. So that wasn't welcome.

However, the motor is running strong, reliable and I'm very pleased with the end result.

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post #51 of 55 Old 09-22-2014, 03:43 PM
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Yeah your better off doing a overhaul on it while it's in working condition.
I didn't have the option at the time to do it on mine since it was my DD.
You gonna pick up new head bolts? I've seen debate on reusing old ones but never found a true answer to it.
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post #52 of 55 Old 09-22-2014, 04:24 PM Thread Starter
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ARP head studs are the way to go. Subaru's OEM stretch bolt system has many weaknesses.

Arp 260 4701 Head Stud Kit Subaru Impreza WRX STI EJ20 EJ25 DOHC 2 0L 2 5L | eBay


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post #53 of 55 Old 10-07-2014, 12:19 PM Thread Starter
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Getting barely rated boost now with the exhaust manifold to turbo up-pipe gasket repair. Rated boost is 16.5psi =/- 1.0psi.



We confirmed that my TD04 turbo can produce 22 psi when not throttled back so it's still healthy, and not limiting boost in this situation. So it looks like it's the boost controller that isn't keeping up with the Stage 2 tune requirements, and we'll replace it in due course.

I heard that some stock boost controllers aren't up to holding Stage 2 boost levels reliably, so my issue here is consistent with that.

Here's a picture of the exhaust gasket that was leaking, and from Grimmspeed's writeup this is a problematic exhaust plumbing joint to get sealed well.



Their solution is a double thick replacement gasket, which sounds like a good idea.


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post #54 of 55 Old 10-07-2014, 04:14 PM
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You pretty much get what you pay for when it comes to gaskets.
I went with GS replacements as well for exhaust.
Hella thicker than OEM for sure. :-)
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post #55 of 55 Old 10-07-2014, 05:23 PM Thread Starter
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That's definitely true of this one, Chuck

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