aigochamaloh Posted August 10, 2015 Share Posted August 10, 2015 Well, against my better judgment, I bought a used AVO turbo kit from the forums and this is my install journal. Yes yes, "why turbo the 2.5i, sell it and buy a LGT!" LGT's are old now, they will probably need a rebuild soon, so I'll spend the same money rebuilding vs putting this turbo on. I've owned this car since day one so I know the complete history about it. It has 125k miles on it and the suspension is mostly done. It's sitting on RCE Tarmac coilovers, AVO sway in the back, and completely refreshed ball joints, tie rods, etc. Now that the wife friendly WRX (CVT, blah) is the daily driver, I can tinker with the Legacy and track it after buying some tires. Funny enough, my wife just told me to get rid of the Legacy and buy a BRZ or FRS or something like that, but I don't feel like paying for another new car, spending money on upgrades, plus this car has been paid off for several years. Anyway, before work this morning, just pulled the car into the driveway and started taking the easy stuff apart. Bumper skin off, pertinent exhaust pieces off, and all intake pieces off. ECU dumped and emailed away. Not bad for an hour's work I suppose. http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0810150848c_zpsfcekk6cd.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0810150848b_zpstuqogsvb.jpg Intercooler was damaged in transit. Claim with FedEx pending, but I will probably paint it matte black and install as it is for now. http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0728151939_zpsmh1rseog.jpg Will try to pull the oil pan tomorrow to swap it out for the tapped pan I received. Need to send WRX injectors off to WitchHunter to get cleaned and tested. Also need to buy new gaskets for the stuff I took off, as well as oil pan sealant. Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 10, 2015 Author Share Posted August 10, 2015 Put the downpipe on. Fits well, with all holes lining up correctly. Unhooked the main engine harness and took it off the metal brackets and off the zip ties on the firewall and etc. Going to be interesting routing these so that they don't melt from the downpipe and turbo. Collector is super close to the AC pipe as well. http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0810151559_HDR_zpsw5bkdfvp.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0810151559_zpswiv9jrww.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0810151559a_zpsyvam2qys.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0810151600_zpsqopy5ucw.jpg Link to comment Share on other sites More sharing options...
GEE-OTTO Posted August 11, 2015 Share Posted August 11, 2015 Makes perfect sense LGTs are getting old and folks are starting to dump them off for fear of a rebuild in the near future. And you will spend less than a rebuild of a 255 installing the kit. Great to see another owner doing this project! Is the DP contacting the AC line? Link to comment Share on other sites More sharing options...
GEE-OTTO Posted August 11, 2015 Share Posted August 11, 2015 Also dont forget the fuel pump! Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 11, 2015 Author Share Posted August 11, 2015 Also dont forget the fuel pump! Yup, putting in a DW65C. Waiting on my fuel pump gasket from the dealership. Today, I took off everything to get to the fuel injectors. Changed the spark plug wires while I was at it. Thinking I may just replace the spark plugs as well. I think they've been on for about 50k miles. Need to get some Permatex gasket maker and drop the pan tomorrow. I'm also missing the AVO MAF adapter for the kit, any generic ones I can use? Link to comment Share on other sites More sharing options...
west_minist Posted August 12, 2015 Share Posted August 12, 2015 THe gains could be a little small since it wasnt design to make power, but its a nice little project. You may have to strengthened a little to make a little more power out of her. Link to comment Share on other sites More sharing options...
GEE-OTTO Posted August 12, 2015 Share Posted August 12, 2015 THe gains could be a little small since it wasnt design to make power, but its a nice little project. You may have to strengthened a little to make a little more power out of her. Gain the kit makes 100hp over stock on a fairly conservative tune. For what he paid used the hp to dollar ratio will be closer to that of upgraded LGTs (upgraded turbo vs power yield) Link to comment Share on other sites More sharing options...
jasejase Posted August 12, 2015 Share Posted August 12, 2015 Not flaming anyone, but.... Aren't 2009 2.5i's getting just as old as 2009 lgt's? Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 12, 2015 Author Share Posted August 12, 2015 Not flaming anyone, but.... Aren't 2009 2.5i's getting just as old as 2009 lgt's? Lol ya ya. But the NA had an "easy" life. Link to comment Share on other sites More sharing options...
jasejase Posted August 12, 2015 Share Posted August 12, 2015 Ohhhhhhhhh. Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 12, 2015 Author Share Posted August 12, 2015 Ohhhhhhhhh. Hahaha, it's simply a matter of being bored with money to waste. Stupid hobby right? Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 12, 2015 Author Share Posted August 12, 2015 Oil pan off today. Waiting on o-rings and gaskets from dealer before putting new one on with Permatex Ultra Black. http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0812151011a_zpshcqiizoz.jpg Link to comment Share on other sites More sharing options...
jasejase Posted August 12, 2015 Share Posted August 12, 2015 Hahaha, it's simply a matter of being bored with money to waste. Stupid hobby right? Oh, I know! Link to comment Share on other sites More sharing options...
GEE-OTTO Posted August 13, 2015 Share Posted August 13, 2015 Not flaming anyone, but.... Aren't 2009 2.5i's getting just as old as 2009 lgt's? You and your conclusions based on accurate observations and knowledge of the 4th gen legacy Link to comment Share on other sites More sharing options...
GEE-OTTO Posted August 13, 2015 Share Posted August 13, 2015 Oil pan off today. Waiting on o-rings and gaskets from dealer before putting new one on with Permatex Ultra Black. http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0812151011a_zpshcqiizoz.jpg HGs look clean! While its off check the oil pick up for hairline cracks specifically around the mounting flange. those bolts near the back of the pan can be assh0les nice method to gain clearance without a engine hoist. Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 13, 2015 Author Share Posted August 13, 2015 HGs look clean! While its off check the oil pick up for hairline cracks specifically around the mounting flange. those bolts near the back of the pan can be assh0les nice method to gain clearance without a engine hoist. Well, the passenger side head had some crud on it. Didn't see it last time I was under there. Cleaned it up and will watch it. I don't have any loss of coolant, oil is clean, etc. Yes, just undo the two 14mm nuts for the mounts, then jack the engine up by the oil pan, put 2x4 blocks under there, and let the jack go. You have plenty of space for all the bolts. Will definitely check for a cracked oil pick up, but I have never heard of a failure in the NA crowd. Changed the fuel pump this morning. Tank looked good, no corrosion or anything crazy inside. Make sure to get a new gasket for the assembly or you will smell gas forever. Installation of the pump is straightforward. This is a very good walkthrough, so I didn't take any detailed pictures. http://forums.nasioc.com/forums/showthread.php?t=2303133 Just make sure you don't have pieces left over after your done (isn't that always the case.) And make sure you secure your new filter to the pump with the little star clip. Bolt it up and click your car over to on without starting the car to prime the pump. If you didn't screw up, you shouldn't have gas spraying all over the inside of your car, and hopefully, your fuel level comes back and registers (delicate fuel level assembly.) Luckily, nothing went awry with mine, and the DW65C is so simple. It's nice that is a drop in pump replacement. I just forgot I had undone my injectors, and the pump dumped fuel all over the ground in front. Oops. http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0813150841a_zps38hyrqox.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0813150849_zps6vsiglb2.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0813150849a_zpsfycwqakk.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0813150859_zps4qdkqcok.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/Legacy%20Turbo/0813150909_zps6kjkyi3a.jpg Link to comment Share on other sites More sharing options...
GEE-OTTO Posted August 14, 2015 Share Posted August 14, 2015 Nice! Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 14, 2015 Author Share Posted August 14, 2015 Gasket and dipstick orings came in for the oil pan so put it on today. Very tight, even with the added clearance. Noticed some Ultra Black rubbed off onto the flywheel cover in the back, so only time will tell if the oil pan is sealed well enough. New drain plug washer and the good old Fumoto back on. What a PITA, probably the worst part of the swap (either swap the pan or tap the pan, my used kit came with tapped pan). Looks like this tap is exiting towards the passenger side exhaust ports, but should be ok with the angle the tap is. Will probably use header wrap on the oil line there and the AC line up top. http://i207.photobucket.com/albums/bb227/aigochamaloh/0814151508a_zps427ro4cf.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/0814151508_zpsjpwakeau.jpg Link to comment Share on other sites More sharing options...
jasejase Posted August 16, 2015 Share Posted August 16, 2015 You and your conclusions based on accurate observations and knowledge of the 4th gen legacy Yes sir! Owned 3 of them over the course of 3 years. Na and turbo! I'm an expert and whatnot. Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 18, 2015 Author Share Posted August 18, 2015 O hai there. http://i207.photobucket.com/albums/bb227/aigochamaloh/0817151716a_zpsewuyvp8d.jpg http://i207.photobucket.com/albums/bb227/aigochamaloh/0817151716b_zpskv5emldl.jpg Link to comment Share on other sites More sharing options...
GEE-OTTO Posted August 18, 2015 Share Posted August 18, 2015 Yeah so that oil line where does it tap from?? I think i know but ive never been sure Just want to make sure for when the time comes lol. Also how long did you allow the oil pan seal to cure? I guess it is trivial since its taking multiple days for the install. Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 18, 2015 Author Share Posted August 18, 2015 I just placed the turbo temporarily. Getting new oil and coolant lines, as well as bolts and nuts. The packaging says let it cure for 24 hours. Link to comment Share on other sites More sharing options...
VrpDCNzZfIOS Posted August 20, 2015 Share Posted August 20, 2015 Great writeup. I am a fan. I love that you are doing an N/A. Sent from my SM-N910T using Tapatalk Link to comment Share on other sites More sharing options...
aigochamaloh Posted August 21, 2015 Author Share Posted August 21, 2015 Got my injectors back from WitchHunter today, probably wasted my money, because the injectors pretty much flowed the same (near 100%) before I sent them in. But new seals and piece of mind, good things I suppose. I started to fill the oil pan and it started pouring out of the return boss, which kind of surprised me. I'm still waiting on my new stainless steel lines, but figured the return should be above the oil line. I guess the car is tilted because it's on jackstands, but still surprised me haha. Good thing it was cheap oil I was going to change after 500 miles or so. I hope the oil level in the pan isn't above the return line, otherwise that could be a problem. Link to comment Share on other sites More sharing options...
Agent_Orange Posted August 25, 2015 Share Posted August 25, 2015 New to the forum... subbing for hopes and dreams of a 2.5t in my OB Link to comment Share on other sites More sharing options...
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