05 Subaru WRX Hybrid Engine build Ej2.0/EJ257

Hello, this blog is for anyone who finds it interesting or useful.. Please disregard any grammar errors, this is just coming out of my mind, and im not going to have anyone edit this for me, so deal with what ever my mind spews forward..
Here is a quick run down on the car and the situation leading to this overly costly and in-depth engine build...

Feb of 2010 in Peoria Il, we had a superb blizzard.. and hell, I've got an AWD fun car... put two and two together in any gear headed American boy and you can figure out the rest.

Well two months before my "incident" I had a local dealer change out my timing belt, and guess what they forgot to do, they didn't plug my radiator cooling fans back in. I put 1500 miles on the car since the timing belt install, in the dead of winter and only short little in the city driving. So I had no inclinations that the car was going to overheat the first time I put her under a load.. Well I did a few doughnuts at 6500-7000 RPM and overheated so quickly that I was unaware that id spun a rod and basically destroyed every bearing surface that oil touched. "keep in mind, I'd only redlined for 30 seconds" I mean total destruction. So I am going to blog this build and post any info I think someone might find useful. Feel free to email me with any questions.

FYI this build is the single most costly engine I've ever put into my personal car. Here is a cost list that is about 95% complete.
This is an excel doc, I just copied and pasted it here. This is some of the info that Ive cept track of during this build and some quick ref Torque specs and stuff. Hope someone finds it useful.

2005 Subaru WRX Engine Cost Tracker X= Purchased XX=Recieved
Pg. 1 of 2 Finnish this f*^king car!!!

XX Ej257 block XX x $2,500.00
Wiseco Forged pistons $550.00
Heads Mechined Port & Polished
BC Double spring Valve train w/ 272 cams
STI Shimless buckets.
Gates Full Timing belt w/ Pulleys & Hardware.
Winners Circle Royal Purple Break in oil 10w40 $71.29
Advanced Auto Rear Main seal FelPro $10.99
AutoZone Fuel Filter Autozone $20.00
Advanced Auto Cam Cover Gasket set ??Re-Use??
AutoZone clutch alignment tool $20.00
clutchmaster clutch alignment tool $(16.00)
Ended up buying a universal clutch alignment tool kit. $45.00
Pyrometer EGT Gauge Link In email WRX Parts 122.99 $122.99
Steering Column Dual Gauge Pod ATI. $94.98
Turbo Coolant Line adapter. $60.00
Dash Gauge Pod $54.00
BOV gasket cut my own $7.00
Throttlebody Gasket cut my own!!!
TurboXs Knock Light $129.00
eBay 9 Piece Hose Kit BLUE '02-'05 Subaru Impreza WRX $159.00
eBay ?? 50/50 BOV TurboXS $173.30. "POS"
eBay ?? Carbon Fiber STI Hood scoop $177.00
eBay ?? STI Rear Spoiler $110.00
eBay ?? Swaybar kit Eibach $264.00
kstech XX TGV Delete Gasket set Need 2!!!! XX $24.00
eBay XX Intake gasket set Need 1 SET!!! XX $13.00
XX GrimmSpeed 3 Port Electronic Boost Controller XX $99.29
X Oil Fill cap X $12.99
X Turbo Heat blanket X $62.49
eBay X Dash Gauge Pod X $204.99
eBay X O2 Sensor Denso X $154.95
eBay X Oil Catch X $19.00
eBay X Hose Heat Shield 3/4" $34.83
eBay X Red Wrinkle paint Dress up Engine bay!!! 2 Cans X $22.63
eBay X Header wrap X $44.25
eBay X INJEN Cold Air X $60.00
KSTech MegaMAF 73mm short MAF intake $201.07
X 25 3/16 Header Stainless Steel Ties Shipped to My House X $17.49
eBay XX Inovate iPhone data logger READ reviews first XX $165.00
eBay XX Intercooler intake Hose 2.75" XX X $6.00
eBay XX Agency UpPipe XX X $170.00
eBay XX Header Wrap XX X $43.84
XX Motor Mounts XX $238.00
XX Phenolic Intake Gasket XX $40.00
eBay XX Sylicone intake tube XX $80.00
eBay XX Clutch Throwout bearing XX X $42.00
eBay XX Turbo Gasket / Braided hose install Kit XX X $55.00
eBay XX Boost Gauge XX X $44.99
XX Oil Pressure sender re-location adapter XX X $44.95
eBay XX 52mm Oil pressure guage XX X $107.99
eBay XX AEM A/F Gauge XX X $168.79
XX Water temp sending unit adapter XX X $35.10
eBay XX 52mm Water Temp Gauge XX X $83.00
eBay XX 255LPH fuel pump XX X $49.98
Scott XX Titanium Front strut Brace XX $81.25
Scott XX Up-graded Intercooler XX X $81.25
Scott XX STI Intercooler Sprayer XX X $81.25
Scott XX KartBoy Short Shifter XX X $81.25
TOTAL $102.28 $5,704.62 $1,371.27
Grand Total $7,178.17
need to call for a Tune? R & T's Unlimited Inc (309) 683-3566

Engine Install steps. / Checklist
Sand and Paint Intake Minus the TGV Risers.
Pull Timing cover, check to see if metal Corner Guides are installed!
ME(H4DOTC) Pg. 48 Double check Timing.
ME(H4DOTC) Pg. 29 Pull Cam Covers check valve lash
Valve Lash Intake .20+->02mm (.0079+-.0008) Exhaust .35+->02(.0136+-.0008)
Install Transmission Mount.
Flash New ROM, (Edit for TGV Delete!!!)
Over Clean Engine to chassis Ground.
Re-Torque Knock Sensor
Re-attach Wire Harness to intake.
Plumb the Vacuum to Fuel supply line. (Vapor Can)
Wrap New Up-Pipe
Port Match the Bottom of Turbo. 45degree
Torque Header, Up-Pipe and Motor Mounts.
Crap New L/O Add 5qt oil to engine, slosh back and forth, NO Full Rotation!
Then Drain, Pray all loose particulats came out.
Trans Studs!! When Engine is on Hoist!!! Install the 4 Bell Houseing studs!!!
Change Rear Seal. Grease Crank!!!
Install Flywheel, Clutch and Pressure Plate.
Call Innovate and or AEM to find out about Wideband Data logger compatability
Install all Gauges. Pray Dash Pod is in!!! WTF yo

Head Torque card [ME(H4DOTC) Mechanical.pdf] Pg.62 of 98
Intake Vac. Ref PDF= FU (H4DOTC) Fuel Injection
Torque Referance Card
Oil Pan 3.6 ft lb
Header 28.9 ft lb
Up-Pipe 26 ft lb
Turbo Oil Bango 11.6 ft lb
Turbo Coolant Bango 25.8 ft lb
Turbo To Up-Pipe + Turbo to Down-Pipe 26 ft lb
Motor Mounts to Block 25.8 ft lb
Motor Mounts to Chassis 62.7 ft lb
Knock Sensor 17.4 ft lb
Intake to TGV 6.1 ft lb
TGV to Head 18.1 ft lb
Throttle Body 15.9 ft lb
Flywheel to Crank 52.8 ft lb
Pressure Plate to Flywheel 11.6 ft lb
Crank Pulley ? 94.0 ft lb
Clutch Fork Cover Plug 32.5 ft lb
BOV to Intercooler 11.6 ft lb
Spark Plug dry and clean. 1/3rd less torq. if lubed!!! 15.2 ft lb
Spark Gap Stock Plus NGK: PFR6G .031"
Have, Stock Heat range . Iridium BKR6EIX 0.03
one range colder NGK BKR7EIX 0.03

Pg. 2 of 2 2005 Subaru WRX Engine Cost Tracker X= Purchased XX=Recieved
Tools May need to buy for engine pulling Still Need Already Have Optional
25 Wide header SS Zip Ties $23.98
eBay XX Engine shop Crane Cherry Picker XX X $199.99
XX Cherry picker Load Leveler 2000lbs XX X $40.28
HbrFreight XX Engine Stand HarborFrieght XX X $65.00
XX Top Box tool chest XX X $300.00
eBay XX 1/2 Torque Wrench XX X $95.00
XX 3/8 Torque Wrench XX X $47.99
Feeler Gauge offset $12.94
Feeler Gauge $5.90
XX 22 PIECES DIAL INDICATOR POINTS SET XX X $7.95
XX Aerospace Dial Indicator Graduated .001-1 2 NEW XX X $55.00
XX Toyota/Honda/Nissan/BMW/VW/Audi Valve Spring Compressor XX X $47.57

Items to Re-Sell
eBay XX New OEM thermostat XX X $25.88
eBay XX 11mm Oil Punp XX X $135.00
eBay XX Water pump XX X $75.99
eBay XX ARP Head Studs XX X $110.00
Jegs XX Instrument Cluster Bezel POS! Returned for refund. $92.98 XX X $(92.98)
eBay XX 50/50 BOV returned POS $94.00 XX X $(94.00)

Compression Engine Compression Test info. Perform W/ Warm engine.
Remove all plugs,
350 RPM Fully Open Throttle, standard: 161-189 PSI
Low Limit = 138 psi Difference between cylinders < 7psi.
Fuel Pressure Disconnect Fuel Pres. Regulator Vacuum hose.
Disconnected Vacuum. Pressure should be. 41-46 PSI
Connected Vacuum. Pressure should be 33-38 PSI.


Let me explain the engine removal particulars. This is not as daunting a task as I'd first thought it to be. But proceed at your own discretion .

04 to an 07. I realize that there are other ways to accomplish the removal, but here is my order of process.

This procedure has a difficulty level of 8-10. If you don't know your way around the tool box then have a shop do this work!!!


All input and comments are welcome, I’m sure I missed something.

Tools…
Engine Hoist
Floor Jack
Jack Stands
Screw Driver, Flat and Phillips
10mm Socket
12mm Socket
14mm Socket
12mm Wrench
14mm Wrench
Short and Long extension
Universal Joint
Pry Bar
Breaker Bar
14mm Hex, 10mm on older models
Heavy Pliers
Hose Clamp Pliers
Drop cloth
Drop LIGHT.

Procedure…
1. Unplug Fuel Pump Relay
2. Loosen Gas Cap
3. Start Engine, Allow it to stall, Crank some more. (Releases fuel pressure)
4. Remove Battery
5. Remove Strut Bar (If Installed)
6. Remove Intercooler (Provides easy access to the turbo area)
7. Remove all visible fasteners from the turbo/downpipe union
Lift Vehicle
8. Unplug Rear O2 Sensor
9. Remove remaining nut from the turbo/downpipe union
10. Remove fasteners from the downpipe/intermediate pipe union
11. Remove Down Pipe
12. Remove lower engine Bell Housing bolts
(NOTE) the studs through the bellhousing. They are studs because the bolt length would prevent removal due to CV shaft interference. SO MAKE SURE YOU HAVE THIS IN MIND WHEN YOU PUT THE ENGINE BACK IN!!!

13. Remove Motor Mount Nuts
14. Drain Coolant by opening the radiator petcock. You will need a large drop cloth. I prefer to drain the coolant in the driveway, I capture as much as I can, though you'll always have a mess. I'd rather it be outside of my work area.
Lower Vehicle
15. Remove the throttle and cruise control cables from the throttle body. Remove electrical connections to alternator, crank sensor, AC and power steering
16. Remove Upper and Lower Radiator Hose from engine
17. Remove coolant lines leading to the filler tank (passenger side)
18. Unplug Fans
19. Remove the Radiator
20. Remove the stock Air Box (if installed)
21. Remove the alternator belt guard
22. Loosen the belt tensioner for the AC belt, Remove Belt
23. Loosen tension on the power steering/alternator belt and remove
24. Remove reservoir hose from Power Steering Pump
25. Remove Power Steering Pump from engine and set aside.
26. Remove Alternator. Remove Air Conditioning Compressor Set aside where battery was
27. Remove Coolant Filler Tank from engine
28. Remove Bracket holding power steering lines to engine. (passenger side)
29. Remove Boost Controller vacuum lines. (passenger side)
30. Unplug Front O2 Sensor (passenger side)
31. Unplug Engine Harness (Both Sides)
32. Remove the Fuel Lines and Vacuum line to the fire wall and Master Cylinder (driver side)
33. Remove Pitchstop
34. Remove Starter (driver side)
35. Remove Heater Hoses from fire wall (driver side)
36. Remove the remaining bell housing bolts
37. Expose the Clutch Fork Shaft by removing the hex plug. (14mm Hex needed, or 10mm on some models) (driver side below starter) Remove the shaft by installing a temporary 10mm bolt into threaded hole and yank. Disengage the Fork from the Throwout Bearing prior to engine removal

Now you are ready to remove the motor (Do the following)
38. Attach Hoist
39. Position a floor jack underneath the transmission.
40. Lift the engine a bit with the hoist, then raise the jack to the tranny. This will balance the load on the input shaft of the tranny. Never allow the full weight of the engine to rest on the jack. Let the hoist do the work. .
41. Repeat until the engine mount studs have cleared the chassis allowing free forward movement of the motor.
42. Have a friend help with this step. Pry the engine from the tranny while very slowly pulling the hoist forward. Have someone there to catch the motor when it releases.

Tada! Its out.

I imagine that installation is in reverse order. The only thing to remember here is to attach the fork and throughout bearing assembly to the tranny first prior to mating the engine to the tranny.