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Thread: GROUNDED - Starting an EJ205 Rebuild

  1. #1

    GROUNDED - Starting an EJ205 Rebuild

    It's not fabulous to be without a personal auto.

    Looks like I've spun a bearing at 252,000 km and therefore need a rebuild. I have started working on it previously with Touge Tuning (www.tougetuning.com).

    At the moment I have:

    1. Rebuilt heads with cams,
    2. Spare EJ205 shortblock with oil pan,
    3. Gates timing belt kit, and
    4. OEM Cam and front crank seals.

    I want to rebuild it for tracking, but Iím not planning power upgrades past Stage 2. Intend to deliver what I have to Touge, get a rebuilt long block with timing belt kit installed, and then help Caveman to remove and replace the engine in my gf's driveway in Orillia when the longblock is ready.

    I think I prefer:

    5. 4032 alloy forged pistons,
    6. ARP head studs, and
    7. 'toilet seat' baffle oiling mod.


    Internal components Needed
    -New Bearings (Rod and Main)
    -Forged Pistons
    -ARP Head Studs
    -Head Gaskets
    -Seals

    Should the oil pickup be replaced as well, and what else should I consider?

    Attached Images Attached Images
    Last edited by LaszloT; 06-26-2014 at 09:40 AM. Reason: add image
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  2. #2
    I have an engine hoist and stand you can borrow.

    edit: is the ej20 prone to ring lands? I haven't heard of that.

  3. #3
    Thanks Walter, I'll take you up on your stand and hoist offer. I expect to need them for the Jul 11th weekend.

    The EJ205 does not have ring land issues like the EJ257, and it's the more durable of the two OEM designs. It's the hypereutectic pistons in the EJ257 that are somewhat fragile.
    Last edited by LaszloT; 06-27-2014 at 09:53 AM. Reason: OEM designs clarification
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  4. #4
    Picked up Blake's '04 STi con rods for a sturdier EJ205 build.

    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  5. #5
    Pulling out the spun bearing EJ205 this weekend.



    Spare short block will be delivered to the machine shop Thurs when all the parts (finally) arrive:

    -New Bearings - King
    -Forged Pistons - Mahle
    -ARP Head Studs
    -Head Gaskets - Cometic
    -Seals
    -Crank - Re-Use Original
    -Rods - Use '04 STi rods
    -KillerB oil pickup
    -KillerB oil baffle





    Happy that it's being rebuilt by Canada's version of Crawford Performance, Gord Bush Performance.

    http://www.gordbushperformance.com/

    According to Touge Tuning, who is the performance shop I'm working with, "Gord handles all of the machining and fitting of the parts and we handle the final assembly, timing belt, seals etc."

    So now I have some sort of timeline for the new motor's arrival. Woo hoo!

    Last edited by LaszloT; 07-14-2014 at 12:45 PM. Reason: Add image
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  6. #6
    Shipped the old EJ205 to Touge Tuning for parts swap to the rebuilt motor.



    Collecting the fluids for reinstall. Going with a 20 minute oil change, followed by a 1,000 km oil change.

    Last edited by LaszloT; 07-14-2014 at 12:49 PM.
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  7. #7
    Looks like you've got everything you need. I hope it all moves along well!
    Frank - I drive a Nissan
    #259

  8. #8
    Thanks Frank.

    Here's some tech trivia on forged piston alloys:

    http://www.enginelabs.com/engine-tec...iston-secrets/
    Attached Images Attached Images
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  9. #9
    Spare shortblock was opened up and confirmed that it too has spun bearing issues, requiring a crank- or crank repair- and connecting rod. We had planned to upgrade the con rods with STi items so that's not an issue, and will now replace the crankshaft with an OEM item. Build budget just went up by $550 plus tax.

    "The OEM forged steel crankshaft from Subaru is quite good quality and can be used for reliatively high performance engine builds without concern. 2.0L applications use a 75mm stroke. STI Version 8 and newer crankshafts are generally surface hardened and feature cross-drilled mains to improve the oil flow to the rod bearings.

    Usually ships in 1 to 2 weeks.
    Manufacturer: Subaru" [RalliSpec]

    Last edited by LaszloT; 07-25-2014 at 12:21 PM. Reason: Budget
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  10. #10
    This should be damn near bulletproof by the time you're done!

  11. #11
    Built motor has arrived.



    Last edited by LaszloT; 08-20-2014 at 11:22 AM. Reason: Add specs
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  12. #12
    From bobistheoilguy.com:

    Built EJ205 + Specs - Understanding Break-in Procs

    "You'll find many different recommendations for breaking in a built EJ engine. Here's Cobb's recommendations:

    http://www.cobbtuning.com/Technical-...es-s/70721.htm

    The most popular break-in oil is probably Rotella 15W-40 so you're on the right track there. Motul, Amsoil, and RP break-in oils are good as well. Most don't switch to synthetic until after some of the initial short intervals.

    And the Built Motor forum at nasioc is a good resource:
    http://forums.nasioc.com/forums/forumdisplay.php?f=144

    Just don't be one of those guys that doesn't follow the builders' advice and ends up needing a rebuild.

    -Dennis"

    I was planning to run this Rotella T for the recommended break in:

    1. 20 min oil change - warm for 10 min, run at 2000 rpm for 5,
    2. 100 km oil change - intentionally vary the rpms constantly in this first drive, but do not to exceed 5500 rpm, and
    3. 1000 km oil change - avoid constant rpm running.

    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  13. #13
    We are back in action after 2 months without wheels. Man I miss driving this machine!





    A bad clutch release bearing caused a few dry run installs which wasted time, but aside from that it went smoothly after we got the built motor.
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  14. #14
    Awesome!!

  15. #15
    Here's us pulling the built motor one of the numerous times - sometimes in the dark - when the clutch bearing wouldn't activate the clutch.



    And I even did some work myself - like holding the light when it got dark. Ha ha.



    It's running strong now on a Stage 1 tune until the 1000 km oil change. After that we'll kick it up a notch, just in time for working the Sept 7 ATTS Beginner Lapping Day at the DDT.
    Last edited by LaszloT; 08-26-2014 at 06:29 PM. Reason: Running well now
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  16. #16
    EJ205 header is wrapped now. Lower underhood temps, more efficient turbo and Cat operation, and reduced heating of the oil filter. The Lava thermal wrap was a gift from the Performance Shop, and it worked great!

    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  17. #17
    My built EJ205 is now properly broken in and running on it's 91 Octane Stage 2 tune.

    Because of age, we are replacing some of the tired intercooler plumbing on the turbo discharge side, items 5. air intake duct, 7. BOV gasket and 10. y-pipe in the diagram below:




    Then we'll be "Ready to Rock"! Ha ha.
    Last edited by LaszloT; 09-02-2014 at 10:01 AM.
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

  18. #18
    At what point does the stock exhaust manifold become a big restriction? Is the bigger gain faster spooling?

  19. #19
    It's not that bad with the OE WRX turbo. Most data on gains are from the 2.5L block or large turbos, and then results depend on the quality of the piece. Cheaper Ebay headers are known for fitment problems and cracking.

    http://perrinperformance.com/i-13323...5-wrx-sti.html

    Bang for the buck, new turbo is definitely the best hp / $.


    Stephen - I drive Blue Subarus of the rally and track varietals.

  20. #20
    A full day at the track running with the big boys in the Instructor's run group - the built motor WRX is working marvelously. Same Stage 2 power as before and it feels similar to the 252,000 km motor it replaces.

    I had a ton of fun!

    Last edited by LaszloT; 09-08-2014 at 12:53 PM. Reason: feels similar
    Laszlo - red '17 WRX
    The all-new Subaru WRX is coming. Pardon our dust.

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