jersdunz Posted November 3, 2016 Share Posted November 3, 2016 Hi all, I recently bought a Car that grenaded a turbo while on a test ride. The engine consumed 3 turbos before the dealer threw in the towel. It was fresh detailed when I brought it home and the interior is awesome considering 175k on the clock I Brought it home for the painfull price of $1600 I has a 5EAT trans stock wheels/tires, The only evidence of being owned by a child are the really cheap EBAY HID Lights that are installed. I will be adding lots of pics I Have been reading and watching everything I can find online. But I'm still in over my head .. I am going to use this first post to try and populate the mod list as I make them. I'll do my best to make everything mentioned that is available online include a link. A lot of the stuff regarding the turbo will be fabricated and I'll at least include photos of that stuff. Short Block OEM - CRANK SHAFT MANELY - CONNECTING RODS MANELY - PISTONS ARP HEAD STUDS GATES WP/TIMING SET OEM OIL PUMP ACL RACE BEARINGS OEM ENGINE GASKET SET OEM OIL COOLER MOROSO - OIL PICKUP DIY TGV Deletes Cobb V2 Access Port FRR Full Hose Set BORG WARNER EFR7670 CNT FMIC GRIMSPEED EBCS AVCS Gears Serviced @ outfront Motorsports DW65C FUEL PUMP OEM FUEL FILTER INJECTOR DYNAMICS TOP FEED SET DIY Exhaust Header - Twin Scroll heads reworked by local machine shop stock cams valves etc. Block machining done @ same local shop. Knock list Items in the works / not yet complete / awaiting funds etc.... This list will Grow / shrink As things Come up and or get completed Hexmods 5EAT Valve body magic Hexmods 5EAT Bushing upgrade 5EAT - clutch packs Replaced DIY Vband Down Pipe ( Modified Godspeed ) DIY 3" cat back Exhaust DIY AOS Bottle Drivers Side CV Axle BTSSM android Interface Refurbish, Sand Polish Headlights HID or LED Headlight Upgrade / 15$ ebay hids were quickly recycled Replace front rotors, & Pads all around. Power Steering Lines Relocated. Pro Tune - FNP Tuned Utah - Should include some 5EAT tweaking. The attached file is an Excel file if you want to see my build sheet change the file extension to .xls Its a handy simple spreadsheet that'll help you track completed and incomplete tasks and add the values for you.2005 legacy build sheet.pdf Link to comment Share on other sites More sharing options...
jersdunz Posted November 4, 2016 Author Share Posted November 4, 2016 So i guess some more detail is warranted here. I bought a 2005 Legacy GT automatic with 174000 miles. Pearl white.. its in decent condition... As normal i thought it cleaner than it was while i was hashing out the decision to buy it. PAID JUST OVER 1500 for it... I drove it 3/4 mile to my house... Sounded like a dremel on a steel table... That turbo is trashed. http://i.imgur.com/TGVrlIM.jpg The banjo bolts killed the turbo while it was out on a hard test ride. then they killed 2 turbos trying to get it sold. They claim one of them only lasted a few minutes. The inside of the engine tells about the same story there is a crap load of bronze material inside. http://i.imgur.com/jr4cenI.jpg ------------------------------------------------- http://i.imgur.com/KVpTwEp.jpg ---------------------------------------------------- http://i.imgur.com/AqArkPa.jpg ----------------------------------------------------------- http://i.imgur.com/QIzeaNj.jpg ------------------------------------------------------------- http://i.imgur.com/Tb1DfIN.jpg Link to comment Share on other sites More sharing options...
Max Capacity Posted November 4, 2016 Share Posted November 4, 2016 Your going to need, a new ej257 short block new or used heads that have been rebuilt, I doubt yours are useable. new oil pump new oil cooler engine gasket set for your year car vf52 turbo, it will be fine with your stock fueling, but you'll need a tune You might want to think about anew oil pan unless the machine shop can clean it real good. remove both banjo filters catless up pipe 3" down pipe, Invidia makes a nice piece. read the sticky's and read my click here link in my sig. You'll want to make a list of everything you'll need with prices... You'll want a Cobb AP or if your good with a lap top, the cable to plug into the obd2 port, read the sticky's in the Tuning Forum. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
jersdunz Posted November 4, 2016 Author Share Posted November 4, 2016 Your going to need, a new ej257 short block. Do you think my block is bad from what you've seen? I was going to have the machinist do the bores and determine if the crank could be polished although I wasn't holding much hope on this crank. _______________________________________ new or used heads that have been rebuilt, I doubt yours are useable. I got some parts laser cut today to build my own cam pulley tools so i'll be able to finish removing the heads hopefully tonight. I did put a feeler gauge under the cams and all 4 cams are out on the loose side What has you leaning towards the wasted heads theory. The massive amounts of turbo shrapnel that could have been consumed? again I was planning on having the machine shop go thru them as well. I assumed they would need the full treatment. Are the springs likely to be worn out after 175,000 miles? _______________________________________ new oil pump new oil cooler engine gasket set for your year car all items I was counting on. vf52 turbo, it will be fine with your stock fueling, but you'll need a tune You might want to think about anew oil pan unless the machine shop can clean it real good. I have already contacted JmP6889928 for some prices. I haven't made up my mind on size though. Luckily there is a 4 wheel dyno 2.5 miles from where I live. I have heard that he is expensive though.. yet to be determined.. its a good thing this is not the car I'm needing for getting to and from work. _______________________________________ remove both banjo filters I have that done with exception to the one hiding behind the cam gear covers. _______________________________________ catless up pipe 3" down pipe, Invidia makes a nice piece. I'm going to get some flanges laser cut build some jigs from the factory parts and make my own. probably while i'm waiting on the machine shop.. I've heard they are slow. _______________________________________ You'll want a Cobb AP or if your good with a lap top, the cable to plug into the obd2 port, read the sticky's in the Tuning Forum. This one you have got me on, I haven't made it into tuning land yet. Link to comment Share on other sites More sharing options...
Max Capacity Posted November 4, 2016 Share Posted November 4, 2016 Yes, my biggest fear is you have metal chips every where, the oil cooler will release them over time. Those pieces may have damaged the bearing journals that the cams ride in, the machine shop will be able to tell you if they are ok to reuse. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
jersdunz Posted November 5, 2016 Author Share Posted November 5, 2016 I'm officially crossing my fingers and going to hope that in the very short time it was ran that any damage will be minimal.. Here's to hoping. Here are some pics of the parts I got from the laser operator today.. Tomorrow I'll get my wrench welded up and take it apart.. Tonight there was a sand dune distraction.. so of course nothing productive was done Link to comment Share on other sites More sharing options...
Max Capacity Posted November 5, 2016 Share Posted November 5, 2016 I can see your pictures now, that's a lot of metal. Make sure every thing where oil flows is in great shape. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
jersdunz Posted November 6, 2016 Author Share Posted November 6, 2016 I can see your pictures now, that's a lot of metal. Make sure every thing where oil flows is in great shape. Well, you were right.. Cam journals are all grooved up.. [emoji45] Sent from my SM-G900V using Tapatalk Link to comment Share on other sites More sharing options...
jersdunz Posted November 6, 2016 Author Share Posted November 6, 2016 I'll tell you what I have a great deal of respect to anyone who wrestles these cam bolts out, while in the car.. What a PITA that was.. Link to comment Share on other sites More sharing options...
jersdunz Posted November 7, 2016 Author Share Posted November 7, 2016 No spun mains, several spun rods. http://uploads.tapatalk-cdn.com/20161107/28290e70c3b3fac5edda0b7f99b05f5f.jpg http://uploads.tapatalk-cdn.com/20161107/c523b1dbed1d8a9b7fc84f8ca2bc5cf9.jpg Sent from my SM-G900V using Tapatalk Link to comment Share on other sites More sharing options...
jersdunz Posted November 7, 2016 Author Share Posted November 7, 2016 http://uploads.tapatalk-cdn.com/20161107/cb91fac506f49e23d1cd5fb1e04efbe7.jpg http://uploads.tapatalk-cdn.com/20161107/57f2dd6c3a75451404042f28dab0f292.jpg Sent from my SM-G900V using Tapatalk Link to comment Share on other sites More sharing options...
Max Capacity Posted November 7, 2016 Share Posted November 7, 2016 Is that cylinder #2 ? At that mileage that doesn't look that bad. Doesn't look like much heat in the big ends on the rods. See what the machine shop say's about fixing the crank and new bearings. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
jersdunz Posted November 8, 2016 Author Share Posted November 8, 2016 Is that cylinder #2 ? At that mileage that doesn't look that bad. Doesn't look like much heat in the big ends on the rods. See what the machine shop say's about fixing the crank and new bearings. I HATE TO ADMIT IT but I don't know which hole it was. I pulled the pistons out with zero intention of reusing them and didn't label them?! I am not sure if that will hurt or not.. I did keep track of which rods go where.. I have been previously thinking it insane to consider re-using the stock rods with 175k on the clock but they didn't get burnt and could most likely be taken out 0.010 what are your thoughts on reusing them. I could redirect that money to oil catching. after reading some of the threads on here, I now know they are much better than I had thought they were, I really doubt I'll ever bother to exceed the 325-350hp threshold. Link to comment Share on other sites More sharing options...
Max Capacity Posted November 8, 2016 Share Posted November 8, 2016 I would reuse the rods, they have been heat cycled but not over heated. The machine shop can measure them and let you know. The pistons should be replaced, again after the machine shop measures the bores and lets you know which size stock pistons to buy. The Tune is what's going to save your engine. www.tuningalliance.com is who you want to talk with soon. start getting info from Mike and Brian. Tell them I sent you. If you look in my click here link, you'll see my #2 cylinder. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
StkmltS Posted November 10, 2016 Share Posted November 10, 2016 You seem to be making good progress quickly. Keep posting pics! Don't commit to using forged pistons until you're aware of the pros and cons. I think they're a waste of money much of the time, but that's my opinion. I just don't want to see see you "go forged" only because it's the more fun-sounding option. There are a couple negative drawbacks (cylinder wear and noise) that people don't talk about very often. Maybe you've already decided the pros are worth the cons, if so, great! FYI Crawford Performance sells new OEM A/B pistons with pins and clips for only $25 each. Just think of all the fun things you could do to the car if you spent $460.32 less on pistons My DiySB rebuild Got Misfires? Link to comment Share on other sites More sharing options...
jersdunz Posted November 10, 2016 Author Share Posted November 10, 2016 You seem to be making good progress quickly. Keep posting pics! About the time I finish the Engine i'll hit a progress wall... Because I didn't have Enough cash to meet my goal but i'll figure it out along the way. I won't commit this car to something I NEED to have until i'm done with it. Don't commit to using forged pistons until you're aware of the pros and cons. I think they're a waste of money much of the time, but that's my opinion. I just don't want to see see you "go forged" only because it's the more fun-sounding option. There are a couple negative drawbacks (cylinder wear and noise) that people don't talk about very often. Maybe you've already decided the pros are worth the cons, if so, great I have been weighing those options... I can't do it right away but I want to set it up for at least 350-400 whp, and maybe the sand rails have taught me wrong for this application but I have developed a habit of overdoing things because stuff breaks. The local machinist polished the cam journals, and told me I was safe to order parts. Parts on order ... I have a set of Manley Rods 15024-4 (H-Tuff) on they're way. Along with a new OEM crank from Heuberger . I haven't ordered pistons yet because I don't yet know if were going to be able to get away with a hone. I think I have everything else for the short block coming just need to figure out all the odds and ends that I need to get, to fix the dry hoses etc. for the last few days all I have been getting done is getting lost in build threads ( there are some seriously sick rides built on this web site ) I have had zero interest in even sweeping the floor..lol But i'll get over that soon enough Link to comment Share on other sites More sharing options...
Max Capacity Posted November 11, 2016 Share Posted November 11, 2016 Thanks for the update. your making progress. I gather the machine shop will measure the rod ends and then order bearings ? 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
jersdunz Posted November 16, 2016 Author Share Posted November 16, 2016 http://uploads.tapatalk-cdn.com/20161116/e97f672fdad6d15ee36d264f84a83a47.jpg I wonder if anyone spots the mistake.. http://uploads.tapatalk-cdn.com/20161116/80406771d0489c656063dd04b9551c94.jpg http://uploads.tapatalk-cdn.com/20161116/9c805da474d4f66a8164ec08ccb2ea8e.jpg http://uploads.tapatalk-cdn.com/20161116/e52f0084de4f9d8065bf9deaa5c2a7a9.jpg Link to comment Share on other sites More sharing options...
Max Capacity Posted November 16, 2016 Share Posted November 16, 2016 upside down labels on the bearing box's ? Did you get ARP head studs yet ? 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
jersdunz Posted November 17, 2016 Author Share Posted November 17, 2016 upside down labels on the bearing box's ? Did you get ARP head studs yet ? My mistake was I Ordered 48mm rod bearings.. Needed 52mm The website I used only one 48mm part on the page.. And I clicked on them.. Don't order parts at 2am. :-) http://uploads.tapatalk-cdn.com/20161117/8f473d6c0f3765809d43cbc1bbf305ba.jpg Link to comment Share on other sites More sharing options...
jersdunz Posted November 17, 2016 Author Share Posted November 17, 2016 I think before I start assembling the engine. I'm going to bust out the dremel and do the TGV (Tumble Generator Valve) delete mod.. Link to comment Share on other sites More sharing options...
jersdunz Posted November 18, 2016 Author Share Posted November 18, 2016 http://uploads.tapatalk-cdn.com/20161118/34f1a13f2217c1732dcf49ffe42c339a.jpg http://uploads.tapatalk-cdn.com/20161118/f0a753f71de7370e8ed3516dfbea067c.jpg These assemblies get so nasty... I've been thinking about my avcs pullies, Should I try the local Subaru dealership to have them serviced.. Our send them to out front. I don't have the dimensions to get an alignment tool made so, it's kind of out of my capability. Link to comment Share on other sites More sharing options...
Max Capacity Posted November 18, 2016 Share Posted November 18, 2016 I think when you factor in shipping...the cost is not that much different. Call the dealer and ask how much. I noticed that's a good picture of the crank shaft. I wonder if you could post that in the timing belt DIY thread. There always seems to be a question of where the pistons are in the cylinder. That photo would be a good reference. http://legacygt.com/forums/showthread.php/timing-belt-replacement-2-5t-106809.html 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
jersdunz Posted November 20, 2016 Author Share Posted November 20, 2016 Subaru told me the avcs cam gears are a non serviceable item. They won't open them up. Sent from my SM-G900V using Tapatalk Link to comment Share on other sites More sharing options...
jersdunz Posted November 20, 2016 Author Share Posted November 20, 2016 My poor compressor is getting a work out this week... http://uploads.tapatalk-cdn.com/20161120/c6d6892aecf0a2f9f1fe2a44dcbcaed2.jpg http://uploads.tapatalk-cdn.com/20161120/2285e2027f6deb90a2e2c15bf77b94c3.jpg http://uploads.tapatalk-cdn.com/20161120/fa84ddcbb282cf79391331de1283d80c.jpg http://uploads.tapatalk-cdn.com/20161120/d361ef3979b81545ba95971af51d71bb.jpg So the hack saw is definitely the better way the get this started. File works good but takes a lot longer.. Link to comment Share on other sites More sharing options...
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