So after several months of subaru withdrawal, I finally tore the guts out of my 2002 WRX Wagon in order to inspect a clutch failure.
I briefly entertained the idea of pulling the engine forward and so began the job by draining and removing the radiator. I then thought better of this and pulled the drive shaft and tranny out by the conventional method. After replacing a shredded throwout bearing, I reassembled downpipe, driveshaft, and heatshields, reconnected wires and airflow sensor, and reinstalled the intercooler.
That left the simple task of reinstalling and refilling the radiator.
Finally, I had coolant topped off after running engine and heater. Job done. It was time for a test drive.
5 miles of exuberance on a job well done and the familiar heart in stomach acceleration, then a sudden heat stroke! I nursed it back to the garage and topped off more fluid, burped the line, etc. Repeat; 5 miles then, bam! Busted radiator!
I waited impatiently for a radiator repair, then reinstalled and went through unusual amounts of fluid. Every 5-10 miles the same problem occurred.
So I pulled it all back out and took out the waterpump and termostat. The waterpump looked fine, but I replaced the thermostat and all hose segments on the pump then finally put everything back together.
5 miles and again same problem. *$%#!
Temperature runs normal on these drives and goes up rather suddenly. Before, I thought I had been loosing water, but now it just seems to dump into overflow tank, leaving the reservoir empty after a drive. I've observed a bubbling/boiling sound emanating from the return line through the turbo. Is this normal? Does this return line pass water through the turbo?
What's going on??