Mike's 1991 Subaru Legacy SS

[cj91legss]

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[mike-tracy]

Been so busy with school and other things that my poor engine hasn't gotten any love.

I got in a good 4 hours tonight - got the intake manifold, complete with phenolic spacers in. Found bolts that are the perfect length in my bolt box. You use a normal intake manifold above and below the spacers, so the total added height is around 1/2".

Got the buckets, cams, valvecovers and etc in, and sealed everything up good. Started working on the front side of the engine, but for the life of me, I can't find the driver side inner timing belt cover. All the timing belt stuff is installed except for driver side cam pulleys.

Sunday I'm going to sort through my boxes and condense a lot of stuff - I really don't need 2 oil pans, 125412351 ac and alternator brackets, multitudes of old oil pumps, PS pumps, etc, etc, etc. Fairly certain I have everything I need to complete the engine, just gotta find it all.

Stopped by PIA today and got 4 quarts of Eneos gear oil - they say it's better than Extra-S, but we'll see. I can't find any E-S in a hurry so that's what's going in. $11/qt, so cheaper than ordering E-S on amazon, and cheaper than my other favorite - Redline Shockproof that I get locally.

[cj91legss]

Mike do you think you can keep an eye out in your boxes of stuff if you have this 20G IAC Hardline?

[mike-tracy]

That's an ej20k - see the wasted spark . I do have one. (Pretty sure)

[cj91legss]

If you have that pipe (its also 20H/R) what do you want for it?

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[mike-tracy]

one HUNDRED BEEELLLIIIOOONN DOOLLHAIRS!!!!

Or a driver side inner timing belt cover. Your choice You pick up tho

[Legacy777]

Mike,

How did the coolant passages line up between the different gaskets on the heads? That's where I could have seen an issue.

[mike-tracy]

Josh, I don't have an ej20g.HG to compare to, but the gaskets seem to go on as well as stock IMO. The openinings corresponded to passages without showing any part of trying block. If this works, its caused I have an open deck, the 22t. gaskets lined up well but a couple of areas were only partially open.

You can see the ones I mean on the GIF I made, upper corners around the cylinders.

[Legacy777]

Mike,

I know the deck may be open, but the heads have specific coolant passages that correspond to the gasket. See what I mean in these pics?

http://www.main.experiencetherave.com/s ... eadwork/10

[mike-tracy]

Ruh roh, hadn't thought about the heads. I have one more set of Turbo heads, just gotta find a n/a 22 gasket to compare.

[mike-tracy]

Engine's complete enough to go in:

-I managed to break a stud on two different up pipes.... luckily I had a gutted one someone threw in a combo deal back in the day.
-Missing an L-EX cam pulley, and cam position sensor.
-HG is still a concern, my buddy is coming over tomorrow with the missing parts and a used 22e HG to compare against my other set of turbo heads. Another friend eyeballed n/a gaskets and phase II turbo head's and said everything appeared to line up fine. (crossing fingers) If they don't line up, I'm gonna tear it apart and use factory ej20g gaskets.

Found a different way to route the PCV port off the block that gives me tons of space around the turbo outlet. I'm using an n/a forester IM this time around, and had issues when I used it a couple years back. I'll post pics when it's all setup and looking pretty-ish.

Kimo made me a coolant tank bracket that bolts to the alternator bracket, back in the day, so I'm going to use that. Back to the 4.11 Tranny I had in the car initially - I've made the decision to sell the 91 SS and put my efforts towards the 92 once I get another DD.

Once it's finished it'll be a decent setup:

Full EJ20G engine and above mentioned ej20k tranny with rear VLSD, intercooled TD04 running on stock injectors and ECU. Hardened shifter bushings and a short shifter, misc other upgrades here and there. Near instant boost and the gear ratios are just about perfect for a fun little car.

[mike-tracy]

Engine is in! I checked out a 22E gasket on my set of 20K heads, ad all the main oil lined up perfectly. Coolant passages aren't perfect, but has holes at every spot the heads needed them. If I have to do this again, 20G gaskets are going in.

Still got to hook everything up, swap rear diffs, install driveline, starter, PS pump, alt belt, pcv lines, etc etc. A weekend job, but my daughter's coming over and I'd rather spend time with her.

[randomiam]

Glad to hear its coming back together; Downtime really sucks. I wouldn't argue against the fun daily driver plan either; Your car was still pretty fun with that TD04 on there.

[cj91legss]

Mike, I should be able to bring you the gasket this weekend, if you still need it of course. Is there anything else you need?

[beatersubi]

I might have a cam pulley and cam sensor, if you still need them. Lemme know.
Trade for a 20G ecu?

[mike-tracy]

I got everything I need now, Beatersubi

[beatersubi]

I got everything I need now, Beatersubi

So, its together and running?

[mike-tracy]

Naw, was focused on finals last week, had daughter over weekend, and am now taking off on a road trip. Maybe next week.

[cj91legss]

Cruising thru my area on that trip? I wanna pick up that iac tube from you, havent had time to get there...

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[mike-tracy]

So I got the car back together. I had clamped up a fuel line with a bolt and clamp when the car was apart, and to my surprise, it shot fuel out at me! I didn't wait for it to finish, and I connected the line.

Well, on first startup, car started on the 1st crank! then died about 2 seconds later. I tried again and the engine wasn't moving... I was able to move the crank by hand, counterclockwise has no resistance, and clockwise is easy till I hit the point where I'm fighting the hydrolock... I can hear the air with fluid hissing as I move the crank (against where it hydrolocked).

What do you think? Injectors are all freshly cleaned 22t pinks, with brand new seals from dr injector.

[Legacy777]

Did you try pulling the plugs to get the fuel out?

An injector that isn't seated properly might have let fuel get by to fill the cylinder.

[mike-tracy]

Got the fuel out by pulling plugs. I had a massive leaking injector problem - rear driver side. Got quite a bit of gas to come out. My pintle cap wasn't on, so I grabbed one from a used 22t injector, and replaced the o-rings.

Well, with the injector not leaking anymore, the FPR started leaking hardcore where it mates to the fuel rail. You guessed it, torn o-ring!. With both of those issues sorted, I started her up. Bam! it jumps to redline instantly! WTF! Oh, the throttle cable was kinked in a way that pulled the throttle open. ha ha, I feel dumb.

With THAT sorted, I changed the oil, and it smelled like gas and was really thin. Good thing I remembered, cause gas in the oil can't be good.

Start her up again, 3k rpm idle! OK, adjust tps to spec, it was way off. I took her for a spin, and the car drives nice but kind of stutters in the transition between on/off throttle. Still holds 28-3000 rpm, though inbetween shifts it drops pretty quick, before "catching" itself.

When I do shift, the vacuum gauge reads ~-20inHG until the RPM's go back up, so I don't think I have a leak. No codes active or stored.

Only boosts to 5PSI. Any ideas?

[cj91legss]

It's definitely in safe mode, I hate safe mode...

what's the condition of the maf you're using? Have you checked to see if it needs cleaned?

I still need to meet up with you soon to pick up that IAC hard line.

[randomiam]

Are you using a MBC with it and stock ecu? I'll bring your cable and my laptop this weekend if you wanna play around with some logging stuff.

[mike-tracy]

Stock everything.