WRX Forged Rebuild
04 March 2009, 11:06 PM
#122
well im now just over 200 miles, all is mot and now tax, £220 for 6 months (wrapping government) so im dropping the oil tomorro and i also have a small fuel leak, but for some strange reasons its not constant and only when i start the car i smell it. i can see what it gathers, on top of block passenger side next to inj, but havent seen it coming from inj or pipes to fix it, although i have removed the charcoal canister, so also breather to take is open. i dont think its a massive issue so il keep driving and checking till i find it. im hopinmg by the end of this weekend id have drove 500 miles so i can up my rev range slightly.
05 March 2009, 11:58 PM
#123
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Well the highest pressure AFAIK is when the pump first gets up and running, after which the regulator does its job and regulates. So if you have a small leak, the time you'll smell it is at first start up. At least that's what always happened with me whenever I had a leak. May be leaking from the o-rings that hold the injectors in the rail?
06 March 2009, 06:44 PM
#124
i found it today, both hoses joining onto the rail, old clips off, new clips on, so old sorted, just passed 300 mile mark, all seems ok, engine sounds same as it did before i stripped it, lol, so either its still fooked or there was never the need to forge, i think its the latter and my paranoia is getting better of me, lol, but so far all is well and good.
09 March 2009, 11:14 AM
#126
460 miles and problems, re done my parallel fuel mod due to leaks. and now intercooler pipe keeps blwoing off, and it winding me up. started taking revs up to 4500rpm nice and easy, but it boosts brillaintly and so much power, but then bang, and pipe off, refit, go up road and bang. either dodgy clip due to me disterbing it all yesterday or somthing that i dont know.
the cars idle has gone iratic and it bouncing and cuts out. gonna sort out intercooler piping and hope it cures it due to having a air leak on intercooler pipes.
apart from this its driving better than ever expected, so much grunt even taking time running in, dont need more than 4k revs.
hope this problem is a easy fix
the cars idle has gone iratic and it bouncing and cuts out. gonna sort out intercooler piping and hope it cures it due to having a air leak on intercooler pipes.
apart from this its driving better than ever expected, so much grunt even taking time running in, dont need more than 4k revs.
hope this problem is a easy fix
10 March 2009, 12:28 AM
#127
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LOL you and me both then. I just hit 1.5 bar momentarily on the way to work and BANG the pipe blew off just close the battery. It's where I cut it to insert a hump hose there, but it doesn't have the bump all the way round the circumference of the pipe to keep it on. Wondering where I can get a bump put into the hard pipes or whether just to try double jubilee clipping it?
10 March 2009, 12:45 AM
#128
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just put 2 clips on and that should sort it guys 
what kined of j clips you using heave duty bolt ones or just normal with screw heads on ?? or you could tap the pipe lip with a hammer on the edge to give it a slight lip if it's been cut that could help keep the j clips on
what kined of j clips you using heave duty bolt ones or just normal with screw heads on ?? or you could tap the pipe lip with a hammer on the edge to give it a slight lip if it's been cut that could help keep the j clips on
Last edited by The Stitcher; 10 March 2009 at 12:49 AM.
11 March 2009, 08:14 PM
#130
well i think my engine may b dieing or im very paranoid. strange hollow knock,constant on idel, goes wen u rev up as lil as 100rpm, cud n detonation. i have 2 audio files if sum1 wants to listen 4 me, im laying under car by sump. let me kno ur e-mail so i can send 
12 March 2009, 02:25 PM
#131
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Hi, I was just reading your thread and reckon your problem is too must gasket on your block facings, look at post 38, you've got about 2x the ammount of paste needed to create a seal and the excess has probably ran into the oil way on the right hand of your pic causing baring damage. Seen this happen before.
If you reduced the ammount of gasket before fixing it together ingnore my post as your build looked spot on otherwise.
If you reduced the ammount of gasket before fixing it together ingnore my post as your build looked spot on otherwise.
26 March 2009, 06:13 PM
#133
disaster at 1300 mile, blowing oil smoke like a train, also down on power. 1 of the plugs also caps also disintigrated. and 40psi down on compression on n/s/f piston. due to my problems im thinking bore wash or may av bent a valve. will soon find out. down garge to take it all apart
26 March 2009, 11:16 PM
#134
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hi m8 haven't been in touch for a while hope it all goes ok for you seen the car outside your work the other day thought all must be well good luck speak soon
29 March 2009, 02:58 PM
#136
well the bore seems fine, will need re galzing, and new rings, but the cyclinder behind it that compression was fine on has a score mark, as if the piston rinf has a straight edge, so im taking the half of block to engineers to have a chat tuesday, all i av left to do is remove pistons, block is split, i thought i could leave pistons in and just pull half off, but i cant, i need to remove the 2 pistons, so gotta make a tool again, and they seem solid in there. see how this week goes, but 2nd time is always easier.
all this because i messed up and set fuel pressure to 3.5 standard and then 1 bar from manifold, so it was maxing at 4.5 bar, how stupid cud a av been.
next time, im setting it to 2bar is idle so max at 3bar, run it lean till ecu fitted.
down but not out yet lol, labour of love, lol
all this because i messed up and set fuel pressure to 3.5 standard and then 1 bar from manifold, so it was maxing at 4.5 bar, how stupid cud a av been.
next time, im setting it to 2bar is idle so max at 3bar, run it lean till ecu fitted.
down but not out yet lol, labour of love, lol
14 April 2009, 07:36 PM
#138
phone call from engineers today, a damaged oil ring scored bore so bad i need a new block, which i have sourced from a guy on here. so i just gotta send payment and wait for delivery before sending one block half back to enginneers with rings and pistons for rebore. also changing head gasket to a 1.3mm from a 1.6mm to aid compression. while its out im gonna wait and fit uppipe and headers before running in again, this time 2.5 bar constant pressure vacumme pipe disconnect from fpr. lets hope take to goes well. il post new pics as i go, again, lol
17 April 2009, 06:06 PM
#142
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You sure that the problem isnt because you got the block bored and honed before you had the pistons? I know you said that know what they are doing but no company i know of can bore and hone for oversized pistons without having the pistons there with them.
Regardless i hope that you get your car sorted soon mate
Regardless i hope that you get your car sorted soon mate
07 June 2009, 11:12 PM
#145
been a while since i updated.
the block was different, was a thrust position 3 not 5. api was gonna liner, but then found a thrust position 3 crank off here, cheers brett. so after weeks of waiting iv got the ball rolling again.
crank is due tuesday and bearings from cdf nxt day once ordered, money is waiting.
block is being dropped to engineers tomorro morning for boreing.
also bought a gems ecu, so i can fit that and get simon jgm to remap.
hoping he will come doen and set up a running in map and sort my fuel pressure out, as the fuel pressure was the problem. also buying a sard reg and throwing the fse and upgrading my parallel fuel mod, to better fuel lines, clips etc.
this time around before i drop engine in im fitting harveys headers and up pipe.
with my hybrid fmic, hks induction kit, forged bottom end, sti v4 heads, walbro 255 fuel pump, vf22 turbo, 3" full decat jap speed exhaust, 440cc inj, harvey up pipe and headers and gems ecu with antilag, im hoping to run inj as close to max as safely possible to see what bhp result i get. hoping to also push turbo as safe as possible and achieve 350 bhp. before i get 740 inj and bigger turbo and 6 speed box.
as most of u know, this the the second time around for me. so iv had the heads profesionally shimmed and im also now going from cosmetic 1.6mm gaskets to 1.2 / 1.3 for better compression. as i only achieved 110psi after 1000 miles. which was even accross the board. may have increased in time, but 300 miles later bore wash. but a thinner gasket will aid in compression.
while its out and money willing, id like to fit a lighter flywheel and pulleys and over drive crank pulley. less work for engine.
so as it stands the block and heads will all be build up. but il be saving and waiting to fit headers, up pipe, pulleys and flywheel.
il keep this updated as i rebuild (slowly)
the block was different, was a thrust position 3 not 5. api was gonna liner, but then found a thrust position 3 crank off here, cheers brett. so after weeks of waiting iv got the ball rolling again.
crank is due tuesday and bearings from cdf nxt day once ordered, money is waiting.
block is being dropped to engineers tomorro morning for boreing.
also bought a gems ecu, so i can fit that and get simon jgm to remap.
hoping he will come doen and set up a running in map and sort my fuel pressure out, as the fuel pressure was the problem. also buying a sard reg and throwing the fse and upgrading my parallel fuel mod, to better fuel lines, clips etc.
this time around before i drop engine in im fitting harveys headers and up pipe.
with my hybrid fmic, hks induction kit, forged bottom end, sti v4 heads, walbro 255 fuel pump, vf22 turbo, 3" full decat jap speed exhaust, 440cc inj, harvey up pipe and headers and gems ecu with antilag, im hoping to run inj as close to max as safely possible to see what bhp result i get. hoping to also push turbo as safe as possible and achieve 350 bhp. before i get 740 inj and bigger turbo and 6 speed box.
as most of u know, this the the second time around for me. so iv had the heads profesionally shimmed and im also now going from cosmetic 1.6mm gaskets to 1.2 / 1.3 for better compression. as i only achieved 110psi after 1000 miles. which was even accross the board. may have increased in time, but 300 miles later bore wash. but a thinner gasket will aid in compression.
while its out and money willing, id like to fit a lighter flywheel and pulleys and over drive crank pulley. less work for engine.
so as it stands the block and heads will all be build up. but il be saving and waiting to fit headers, up pipe, pulleys and flywheel.
il keep this updated as i rebuild (slowly)
Last edited by mje_wrx; 07 June 2009 at 11:17 PM.
26 August 2009, 07:04 PM
#146
been a while again, finally got pistons and went to refit today, wrong type, so cdf racing chris who is a top bloke is getting it all sorted for me again, he has patients of a saint, apart from that all iv done is buy gems ecu and all other bits i need. il sort pics out as i build again, always handy as guides for other members building
27 August 2009, 10:40 PM
#147
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been a while again, finally got pistons and went to refit today, wrong type, so cdf racing chris who is a top bloke is getting it all sorted for me again, he has patients of a saint, apart from that all iv done is buy gems ecu and all other bits i need. il sort pics out as i build again, always handy as guides for other members building
27 August 2009, 10:59 PM
#148
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been a while again, finally got pistons and went to refit today, wrong type, so cdf racing chris who is a top bloke is getting it all sorted for me again, he has patients of a saint, apart from that all iv done is buy gems ecu and all other bits i need. il sort pics out as i build again, always handy as guides for other members building
nice to see your getting somewhere
29 August 2009, 01:37 AM
#150
well i had 4 pistons for my rebuild but two got damaged, and ruined block.
bought new block and ordered two new pistons.
The two new pistons i had where different machining and weights to the two original pistons.
so i checked the part numbers to the years the pistons belong too and found out the original two were for 98 on and the new two i bought were for pre 98.
now my original block was pre 98, so id fitted the wrong pistons in my block, which caused all my problems.
so iv now got 2 pistons on order too match the 2nd lot of pistons i ordered to replace that which were damaged.
so il now have 4 new pistons for a pre 98 block which i have.
the other differences in the pistons are stroke height. the new pistons have a longer stroke so more compression than the original pistons i had. explaining why i only had 110psi per cylinder.
cdf raciing who supplied the pistons has been a top bloke through my nightmare and i recomment the company to anyone looking to buy parts.
The problem we faced is my impreza is on the cross over year, which must have caused confusion.
but cdf has rectified all my issues, no argument whatsoever. mistake made and rectified and im very happy now awaiting the arrival of my two new pistons.
chris is a top man, so thanks chris.
also spoke to wiseco technical to clear the matter and make sure everything this tiem will be ok.
with such a low compression and fuel set up wiseco said it was possible the fuel wasnt being compressed in the chamber enough and getting the explosion in the chamber i should have had leaving residual fuel behind which eventually would wash bores and create the issues i had.
mmmm, maybe, who knows, just glad i bought from a company that cares about its customers. cdf racing
bought new block and ordered two new pistons.
The two new pistons i had where different machining and weights to the two original pistons.
so i checked the part numbers to the years the pistons belong too and found out the original two were for 98 on and the new two i bought were for pre 98.
now my original block was pre 98, so id fitted the wrong pistons in my block, which caused all my problems.
so iv now got 2 pistons on order too match the 2nd lot of pistons i ordered to replace that which were damaged.
so il now have 4 new pistons for a pre 98 block which i have.
the other differences in the pistons are stroke height. the new pistons have a longer stroke so more compression than the original pistons i had. explaining why i only had 110psi per cylinder.
cdf raciing who supplied the pistons has been a top bloke through my nightmare and i recomment the company to anyone looking to buy parts.
The problem we faced is my impreza is on the cross over year, which must have caused confusion.
but cdf has rectified all my issues, no argument whatsoever. mistake made and rectified and im very happy now awaiting the arrival of my two new pistons.
chris is a top man, so thanks chris.
also spoke to wiseco technical to clear the matter and make sure everything this tiem will be ok.
with such a low compression and fuel set up wiseco said it was possible the fuel wasnt being compressed in the chamber enough and getting the explosion in the chamber i should have had leaving residual fuel behind which eventually would wash bores and create the issues i had.
mmmm, maybe, who knows, just glad i bought from a company that cares about its customers. cdf racing