Maciek's 2.36L Turbo Build (and boom goes #4 rod bearing!)

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Legacy777
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Re: Maciek's 2.36L Turbo Build (Dyno Sheet 6.13.14)

Post by Legacy777 »

That sucks about the motor. Maybe the crank & bearing issue were tied to the low oil pressure. I guess you just need to determine whether the low oil pressure was caused by something else, which lead to the bearing issues, or vice versa.
Josh

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1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

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macipusy
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Re: Maciek's 2.36L Turbo Build (Dyno Sheet 6.13.14)

Post by macipusy »

I think the low oil pressure and bearing failure are tied together.

The wear on all bearings plus the large amount of carbon on the pistons and always a burning oil smell while driving, all point to a lot of oil going toward the pistons....

So, I'm hoping it was the squirters causing the low pressure. Other then that, I can only suspect a crack in the block at one of the oil galleys pre-bearing....can't think of anything else which could cause this. I would think a clogged galley would give high pressures.

Cams look a little worn as well, but can be polished and reused.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
Tbly89
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Re: Maciek's 2.36L Turbo Build (Dyno Sheet 6.13.14)

Post by Tbly89 »

Hey, just a quick question....How did you get the TurboXS BPV to clear the throttle body? Also has it worked well for you? Im trying to find a good BPV for my 94 Leg SS.

Thanks....
macipusy
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Re: Maciek's 2.36L Turbo Build (Dyno Sheet 6.13.14)

Post by macipusy »

The turbo XS clears on the 93 TW ej22t with the proper BPV adapter flange. I believe I bought it off of ebay a long time. ago. You have to route the air return on top of the TB. I should have some pictures in this thread showing the setup.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
Tbly89
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Re: Maciek's 2.36L Turbo Build (Dyno Sheet 6.13.14)

Post by Tbly89 »

Thanks for the info man. My car has been leaning out at stop lights, and almost stalling. I hope the turboXS fixes the issues cus right now I have the stock BPV, and as we all know it doesn't clear the TB. I would hate to mess with the ECU.
macipusy
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Re: Maciek's 2.36L Turbo Build (Both cars down 11.19.14)

Post by macipusy »

So 2 days after getting back from Colorado with bearing damage on the RSTi, the Turbo wagon decided to drop 3rd gear off the 4EAT....it already had no 4th.

I swapped the transmission to a 58K mile one I had sitting around, and it was all good....for a few hours.

I was driving down a 45mph road, just cruising casually when all of a sudden a huge power loss and 10:1 AFR. Pulled off the side of the road and it felt like it's running on 2 cylinders, won't rev past 3K RPM because it is struggling. It is idling super rough and won't go above 25mph.

I pulled fuel out via standalone, and it was still running rough at 15:1....so I don't think its just over fueling.
When running rough, it's only at 11 inHg, but I would think it's because the cylinder are not all firing to pull the vacuum, like a defective pump.

I swapped coil pack and ignitor....same.
I ran fresh wires from the standalone to the cam and crank sensors....same
Pulled plugs and they are soaked in fuel...tiny gap at 0.022" NGK BKR6ES-11
Fuel pressure seems ok.....primes at 47 psi and drops to 40 psi once the fuel pump shuts off.
Boost gauge reads the same as standalone MAP, so I would assume MAP sensor is ok.
TPS reads correctly in the standalone software.
CTS is showing correct temperature.

The car is set up an a speed density standalone.

Core processes include:
IAC
IAT
CTS
MAP
TPS
fuel pump relay
ignitor out 1/2 and 3/4
injector out signal
cam and crank input

I think that's it.

I'm gonna pick up some brand new plugs and see what happens.


Stuff I still want to verify:

timing belt for jumped teeth
injector for being stuck open

Other than that, I down for suggestions.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
macipusy
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Re: Maciek's 2.36L Turbo Build (Both cars down 11.19.14)

Post by macipusy »

I'm happy to report that I have all the parts to get the ej257 built and assembled with the ej205 heads for the RSTi backup plan.

I did plastigauge measurements on mains and rods.

Mains:
#1: 0.0015"
#2: 0.0019"
#3: 0.0017"
#4: 0.0020"
#5: 0.0018"

Rods:
All are the same: 0.0017-0.0018"

I'm happy with those numbers. The mains are a little high variation even though the journals measured the same across the board at 2.3620" measured with a micrometer. The slightly larger clearances will allow me to safely run up to 350 whp and 400 wtq.

Rods are installed on the crank. The short block is being assembled tomorrow night!

Hope to have the long block mostly together by Thanksgiving. And maybe in the car and running before the first week of December. Probably just need a little fuel tuning and should be good to go.

I'm going to break it in the hard way....the 20/20/20 method.

20 minutes of idle...change oil
20 miles of nice easy driving....change oil
20 pulls/deccels from 2K-5K-2K at 15 psi....change oil
and DONE!

Gonna run 5W-30 with Lucas break in additive this time around vs Rotella 15W-40
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
macipusy
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Re: Maciek's 2.36L Turbo Build (Both cars down 11.19.14)

Post by macipusy »

More progress troubleshooting the turbo wagon.

I installed new plugs with 0.044" gap. Started it and it runs, still rough and rich.

When I lean it out via standalone, it runs a little better. I'm nervous that I'm leaning out 3 cylinders when one is rich....but it's hard to tell. It runs ok at 13:1....any leaner and starts to run rough. When running at 10:1, it barely wants to idle.

It will not boost at all. Basically you touch the throttle and it goes straight to 0psi and stays there, while falling flat on its face and going below 10:1 AFR.

There is a metallic rattling coming from the turbo. The turbo might be done, but why running so rich? Maybe a couple of issues at once.

Any input is appreciated.

Still need to check injector signal wires for a short....a ground short in the injector signal could possibly be causing an injector(s) to be opening more often then it should.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
macipusy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by macipusy »

Got the RSTi back up and running over the Thanksgiving weekend. I broke in the engine in under 50 miles.

Car feels great. I can feel a tiny bit more torque off boost. I'm running it at 16 psi for a little while, before going up to 20 psi.

The car did not need any tuning going from the 2.38L to 2.5L. The AFRs were spot on. I pulled 2 degrees of timing out, just for safety during break in.

For break in I did 20 minutes of idle, 20 miles of conservative driving and then 20 consecutive pulls from 2K to 5.5K to 2K RPMs.

Oil pressure is at 72 psi at and above 3K RPMs and 18 psi at idle.

Vacuum is 19.5 inHg at idle and 24 inHg upon deceleration.

Super stoked to have the car back....too bad it snowed a couple days ago and I'm not able to drive it...damn salty roads.

I will post up some build photos once I upload them.
Last edited by macipusy on Mon Dec 01, 2014 6:04 pm, edited 1 time in total.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
macipusy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by macipusy »

The turbo wagon still pissing me off.

I swapped fuel injectors over the weekend, but it acts the same. Also checked the injector pulses with a Noid light...all of them were blinking the same. About 4-6 flashes per second.

I am really hoping the timing belt jumped, since I'm running out of ideas. I might try to find a $500 winter beater and drive the wagon off a cliff...I'm really starting to hate it.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
'98Wagon
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by '98Wagon »

Sorry about the wagon man! Url come to you...keep it simple.

AWESOME about the rsti! That's gotta feel good!
thewaterboy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by thewaterboy »

macipusy wrote:The turbo wagon still pissing me off.

I swapped fuel injectors over the weekend, but it acts the same. Also checked the injector pulses with a Noid light...all of them were blinking the same. About 4-6 flashes per second.

I am really hoping the timing belt jumped, since I'm running out of ideas. I might try to find a $500 winter beater and drive the wagon off a cliff...I'm really starting to hate it.
Sorry to hear that man. Sounds similar to when my A4's DV or MAF would die.
macipusy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by macipusy »

I found the problem on the turbo wagon.....timing belt did skip.

I was 3 teeth off on the crank only. Cams were timed together, the crank was 3 teeth behind.

YES! Super happy. I was about to burn it up in a fire.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
'98Wagon
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by '98Wagon »

I figured it'd be something simple. Glad to hear it.

Why did it jump you think? To much hp?
macipusy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by macipusy »

Here are some carnage photos from the ej238t failed bearings fiasco.

That's a lot of carbon for 8K miles....on E85. I'm suspecting squirters plus loose pistons.

Image


Main bearings....look very worn, especially #2 and #4 where the squirters originate.

Image


#4 close up...no copper coating left at all

Image


#3 close up...a little pitting on this one. On the crankshaft you can feel a hump where the oil channel is on the bearing.

Image


#1 close up...still has a little copper coating left.

Image


#3 rod...this was the worst knocker...not spun though.

Image
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
macipusy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by macipusy »

Why did it jump you think? To much hp?
I have a few guesses why, but not sure.

It jumped backwards. I would think if it was from power, the crank would be advanced from the cams.

I've been having issues with the torque converter locking up. Feels similar to dumping the clutch in a manual car.
Possibly a combo of new torque converter, newly installed 4EAT and probably lowish fluid level and no timing belt jump guard on the oil pump.

I was not even getting on it when it happened....just barely cruising.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
macipusy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by macipusy »

And some pics of the newly rebuilt ej257 for the RSTi.

ACL Race bearings standard sized,
polished 60K mile crankshaft,
60K mile rods,
used block (decked 0.004" and honed),
brand new ej257 pistons and rings (AABB sizes),
Cosworth 1.5mm MLS 2.0/2.5 hybrid HG,
back with 10mm oil pump (2 shims in relief valve)
new cam seals
new oil cooler assembly
everything else was reused from the ej238t stroker block

After machining, I pulled out all the oil galley plugs. There was cleaning detergent paste on the back of all the plugs. That was a disaster waiting to happen if missed.

Image


Built a crankshaft jig for assembly of rods.

Image


Fresh bearings....that's the color I like to see on the bearing surface.

Image


Main #5 thrust

Image


Assembly time

Image


Image


Image


What a studly short block!

Image



2.5L powah!

Image


Bare long block

Image


Shiny new oil cooler

Image


Boom

Image


and Boom

Image


and Vroom!!!!
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
macipusy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by macipusy »

And the wagon is fixed!
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
SILINC3R
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by SILINC3R »

Purdy!

Nothing like having 2 cars working
Tony
90 LS Spec rio red sold
91 SS rio red R.I.P
90 Mazda Miata
2005 GT SWP
92ss satinsvoice wrote:LOL! that block was like F*** THIS! IM OUT!
mike-tracy wrote:Word. I'd love to get my hands on one of those trannies, but I just can't stomach the cost
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by Reuben »

SHINEY!
Legacy777
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by Legacy777 »

Great work!

Glad to see you got things back working again!
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
macipusy
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Re: Maciek's 2.36L Turbo Build (RSTi is back! 12.01.14)

Post by macipusy »

Just before Christmas, I grenaded the #4 rod bearing on the fresh ej257. I was doing a pull from 20mph to 120 mph (2nd-4th gears), just baselining with my buddies 410whp WRX.
The RSTi was a tiny bit faster at 20 psi, but maybe a little too much too soon (300 miles on motor). All bearings looked great, except for the #4....crank shaft shot as well, worn by 0.006" on that journal.

I needed to take a break from the shit storm. I took the holiday time to separate myself from my work, school and cars. Went to Mexico and did nothing. I was totally refreshed and stress free upon return, and started to prep for rebuild.


Using King 0.001" extra oil clearance rod bearings this time (0.0021-0.0023" rod clearance)
ACL race mains at standard clearance
New ej257 crank shaft
new oil cooler
new oil pan, baffle and pickup tube
disassembled the oil pump and cleaned all metal out

Not sure if I should step up to a 11mm pump because of the extra clearance.

Assembling the crankshaft tonight and shortblock tomorrow....so maybe 2 weeks out to start up.

I'm taking it easy this time....at least 1500 miles before going above 12psi.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
Legacy777
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Re: Maciek's 2.36L Turbo Build (and boom goes #4 rod bearing

Post by Legacy777 »

That sucks about the new motor, but glad to hear you had some unwind time over the holidays.
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
macipusy
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Re: Maciek's 2.36L Turbo Build (and boom goes #4 rod bearing

Post by macipusy »

And both cars up and running again.

Going to take it easy on the RSTi for at least a 1000 miles.
maciek puszynski

01 Impreza | v6 STi RA | 5mt | ej236t
93 Legacy Turbo | TW | 4eat | ej22t
16 WRX | 6mt | fa20
98 Legacy GT | wagon | 5mt | ej25d


2.36L Turbo - RSTi Build
Legacy777
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Re: Maciek's 2.36L Turbo Build (and boom goes #4 rod bearing

Post by Legacy777 »

Woohoo :)
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
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