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Discussion Starter #241
Re: Baron's '05 STi journal!! - **next stage, parts change!**

Okay, so I hit it again tonight to try and progress a little...got the AC compressor off(what a pain) and the turbo heatshield off, as well as the two top bolts....however, of course, you guessed it...another snag that may require some heat....the very far side nut won't come loose at all. In fact, I have rounded off part of it , when I thought I had began to make it loose. Aaaaand even better, the rear bolt on the power steering bracket completely sheared off and the remainder is stuck in the top of the block. I just stood there a stared at it for a while, wondering what to do next.

Good grief, all these problematic bolts are having me feel a little defeated at the moment. Fuck.


On a side note, some pics of my area as stated earlier.





Built these for basic use:


The clearance:
 

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Discussion Starter #243 (Edited)
Re: Baron's '05 STi journal!! - **next stage, parts change!**

Yes I did. This is because the current compressor that was in it is on its way out. When the A/C is engaged the compressor squeals big time. Really loud. When looking at it while on, the compressor wheel grabs and spins with the belt, but then lets go and it spins free as if it were off. It does this every few seconds or so. So either the internals are bad, or the electrical signal cuts out and the magnet disengages. Pretty sure it's not an electrical issue. Either way, I have a replacement unit ready to swap in, and it is much better looking to boot. Nowhere near as corroded as the old one. I had the system/lines evacuated prior to doing this of course.

It's quite clear this car was "stored" very terribly while down in Florida. I'm not at all near having all the top-end stuff off the engine and have already sucked up about 2 pounds worth of debris and literal mouse crap off the top of the block. I knew it was there to begin with, but I am already pissed off about it.

This is my outlet to vent sometimes I suppose.
 

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Re: Baron's '05 STi journal!! - **next stage, parts change!**

Eh... I really cannot see the compressor being on its way out with what, 3x,xxx miles. Did you try tightening or replacing the belt... since it's the belt that squeals? The compressor will cycle when it runs.
 

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Discussion Starter #245
Re: Baron's '05 STi journal!! - **next stage, parts change!**

Just shy of 31,000 actually. I did try tightening it, but did not replace it. The belt looks new, and I'm pretty certain the dealer replaced the belts before I took it. But I can try that as well eventually.

Part of me wishes I had like, a month straight off of work to knock all this out, and a small fraction of me just never wants to look at it ever again. I consider myself an incredibly patient person, but this is quite daunting. A million things are on my mind, most of which are centered around what I'm going to do about all this. And I haven't even scratched the surface here.

I always respected self-builders, but I have a new level of respect for you guys. Seriously, this shit is taxing.
 

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Re: Baron's '05 STi journal!! - **next stage, parts change!**

Honestly, I have found Subaru's to be a pain in the ass. Easy stuff becomes a terror and shit breaks for no reason. I can say I have zero desire to ever buy another.

On another note, I have an impact, compressor, A/C vacuum pump, A/C gauges, and all kinds of other shit. :)
 

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Discussion Starter #247
Re: Baron's '05 STi journal!! - **next stage, parts change!**

I'm really starting to believe that. Never thought I'd say that. Maybe it was the soft spot I always had for the STi, or maybe I just have rose-colored glasses.

Well, I'd love to stop by sometime and pick something up from you if didn't mind(obivously the car is in no shape to move) or you could pop on over to my place and drop some knowledge/drop some shit off. Cold-ass beers provided of course! :)
 

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Re: Baron's '05 STi journal!! - **next stage, parts change!**

Annoying AC self tensioning belt. I wouldn't be surprised if someone used the next size up because it seems like such a tight fit:

 

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Discussion Starter #249
Re: Baron's '05 STi journal!! - **next stage, parts change!**

It's definitely not one of those belts, but it is a Gates; the part number is on the belt, but I'll have to look at it when I get home.
 

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Discussion Starter #250
Re: Baron's '05 STi journal!! - **next stage, parts change!**

Okay, so not too much progress since the last update but I do have the power steering stuff out of the way and the IM almost ready to come off. It would be off already but I cannot get the fuel hard lines out of the way enough on the driver's side to lift the IM up(since they are nestled between runners 2 and 4). So, it's looking like the hard lines need to come off with the IM.

Slowly but surely.
 

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Discussion Starter #252
Re: Baron's '05 STi journal!! - **next stage, parts change!**

I thought that would be the way to do it yes, but when I went to do that, I couldn't get the whole assembly to budge off the block. I am pretty sure that I had everything necessary disconnected and ready to be pulled off, but I will go back and try this.

Got any free time coming up by chance?
 

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Re: Baron's '05 STi journal!! - **next stage, parts change!**

The hard lines are bolted to the bottom of the intake. If you cannot get the whole assembly off the block, the gaskets may be sticking for you have something still attached or in the way.


No idea about any free time currently.
 

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Discussion Starter #254
Re: Baron's '05 STi journal!! - **next stage, parts change!**

Yes I did notice that originally. What I meant was the whole assembly, IM, TGVs and lines; I couldn't get it to move for some reason. But I will go back and try removing it all at once again.

Sure, just let me know sometime.
 

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Re: Baron's '05 STi journal!! - **next stage, parts change!**

This may be a dumb question but you have all the wires disconnected, right? The knock sensor connector, coolant temp sensor connector and the one wire connector that goes to the PS pump are easy to overlook. They probably wouldn't prevent you from being able to lift the manifold at all though.

Also the first time I removed my intake manifold, I had to "persuade" it off with a pry bar. It didn't take a lot of pressure, just a little lift from below to break the gaskets free.

Love the work space by the way!
 

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Discussion Starter #256
Re: Baron's '05 STi journal!! - **next stage, parts change!**

This may be a dumb question but you have all the wires disconnected, right? The knock sensor connector, coolant temp sensor connector and the one wire connector that goes to the PS pump are easy to overlook. They probably wouldn't prevent you from being able to lift the manifold at all though.

Also the first time I removed my intake manifold, I had to "persuade" it off with a pry bar. It didn't take a lot of pressure, just a little lift from below to break the gaskets free.

Love the work space by the way!
Nah, it's not a dumb question, it helps to have others question things or have another set of eyes. But yes, I have all of those disconnected. The PS assembly is still connected but it is unmounted and set out of the way. That first pic of the engine bay is not what it looks like now, I have progressed a bit further.

Seems you're right; I may have to do a little "persuasion" to remove mine. I had a feeling all this time that it was the gaskets' seal to the surfaces that was the culprit; good to know that others have confirmed similarly and that I'm not crazy.

Thanks, I like my area now.... it was pretty dismal in there before what it is now.
 

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Re: Baron's '05 STi journal!! - **next stage, parts change!**

Nah, it's not a dumb question, it helps to have others question things or have another set of eyes. But yes, I have all of those disconnected. The PS assembly is still connected but it is unmounted and set out of the way. That first pic of the engine bay is not what it looks like now, I have progressed a bit further.

Seems you're right; I may have to do a little "persuasion" to remove mine. I had a feeling all this time that it was the gaskets' seal to the surfaces that was the culprit; good to know that others have confirmed similarly and that I'm not crazy.

Thanks, I like my area now.... it was pretty dismal in there before what it is now.
Gotcha!

I like Fel-Pro's gaskets for the intake manifold. They have a special coating that not only helps them seal but also prevents sticking upon removal.

The TGV to head gaskets:


TGV to intake:


The TGV to intake gaskets are nice because they're steel core gaskets so they hold up well to boost. The blue elastomer bead takes the place of the single emboss on the OE gaskets. I port matched mine to the TGV's before realizing I didn't need to because the intake runners were smaller diameter anyhow.

The TGV to head gaskets are steel core as well but have a different facing material.

Sorry to clog up your post with pictures and definitely use whatever gasket you'd like. I don't know how often you plan on pulling the manifold either. OEM works but like I said these are easier to remove in the future if you need to. I did have to drill out the alignment pin holes ever so slightly on the TGV to head gaskets because they didn't want to lay completely flat. After that they fit fine.

A quick lift up with a prybar on the driver side broke both sets of intake runners free of the gaskets on m car. I also had 82ish K miles on mine when I pulled the manifold the first time. With only 31K miles you may find it even easier.
 

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Discussion Starter #258
Re: Baron's '05 STi journal!! - **next stage, parts change!**

Great pics and info there! No, I don't mind you posting them in my journal. By all means, I welcome this stuff, brings attention to my journal more!

As for gaskets on my end though, I won't be using any since I have composite deletes going on. They have rubber rings on both IM>TGV and TGV>head surfaces that act as gaskets essentially. I think they will hold up to boost pressures with proper torquing of the bolts. That said, it's a little unexpected that I'd have that much trouble prying the runners free of the heads considering my mileage. I DON'T want to do this very often.

I think I may do some more teardown tonight depending on how hot it is in the garage. It has been miserable the past several days here in balmy NE. It's crazy how what's essentially prairie land can get so fucking swampy-feeling. The humidity percentage is over 9000. Heh.
 

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Discussion Starter #259
Re: Baron's '05 STi journal!! - **next stage, parts change!**

Well, I had motivation yesterday after work to get out there and take more apart. The IM is now off and I knew what to expect as far as debris and shit on top of the block(which I have cleaned off), but it has me thinking about the big picture here. See below:







Big picture....as in pulling the motor. I know Jason said that it would be trouble, but I can't help but think at this stage and with timing, it would be best to knock out a bunch of things for peace of mind really. The block is in serious need of cleaning. There's corrosion/blowby down in the intake ports, I took the cover off the crankcase port and the flywheel looks like it's seen better days. I've wanted a new clutch anyways for a while now, since the stock one slips at random times, even under light load.

I'm just brainstorming, weighing my options and thinking of what I can do myself versus what I could pay to have done. Maybe sending the block off to get insepcted/refreshed. I'm not talking about a forged bottom end, but at least replacing with fresh OEM, depending on what it looks like in there. I just feel like that would be best at this point; after that I think the motor will be good for years to come since it's now in the hands of someone who cares about it.
 

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Re: Baron's '05 STi journal!! - **next stage, parts change!**

You are WAY over-stressing about all of this. Clean up what you can and put it back together. If the motor is healthy, run it. The car/motor has 30k miles on it... What are you going to replace/freshen up? The most you'll do is break more shit to fix a perfectly running motor.
 
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