Install Disaster aka Sucks to be me.
03-20-2005, 02:55 PM
#1
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Install Disaster aka Sucks to be me.
I finally had some time to install my headers & water injection this weekend.
For the water injection, I located the pressure switch, drilled the 12 liter tank for the pump supply line, and ran the high pressure line into the engine compartment.
I left some minor wiring, as I can't decide whether or not to include an arming switch for the injection.
"Wow, that wasn't difficult", I cheered as I popped open another beer.
Yesterday evening, I moved onto the headers.
This was a bit more time consuming, as the stock exhaust manifold set up is made up of four major components bolted togehter with 18,395 bolts.
Removed the two cats, and ran into the first problem; the downpipe retaining nut closest to the tranny friction welded itself to the stud.
In fact, two of the up pipe flange studs friction welded while I was removing them for use with the header up pipe.
Had to remove the right side motor mount-to-crossmember nut & raise the engine a tad to remove the up pipe and install the integral up pipe from the header assembly.
During header installation, the 2nd problem happened; I managed to put a "not to deep" 2 inch cut in the palm of my hand.
My daughter was climbing over me, instead of walking around me, and I ended up cutting my hand on one of the metal zip ties that secures the header wrap.
"It was you're fault...you were in my way," daughter yells at me running into the house.
The rest of last night is a little blury, due to blood lose & a few more beers to kill the pain, but I do remember Matt Damon, whiskey, and boobies.
Finished the headers earlier today & fired up the car to ckeck for exhaust leaks and what not.
First impression is that the exhaust note is different; not good/bad, just different.
As the engine was running, causing the header wrap to smoke, my son asked, "What's that?"
Smoke from the wrap, I explained.
"No. Not the smoke. What's that?", he asked while pointing under the car.
Dripping oil.
DRIPPING OIL?!
"SH*T!", I said as I turned off the car.
Inspection revealed that somehow during removal/installation, the lower little semi-circle gasket piece(picture attached below) was damaged & pushed in a bit, causing an oil leak.
Anyone wanna bet that the dealer has to order this item & it'll be a week before it comes in?
For the water injection, I located the pressure switch, drilled the 12 liter tank for the pump supply line, and ran the high pressure line into the engine compartment.
I left some minor wiring, as I can't decide whether or not to include an arming switch for the injection.
"Wow, that wasn't difficult", I cheered as I popped open another beer.
Yesterday evening, I moved onto the headers.
This was a bit more time consuming, as the stock exhaust manifold set up is made up of four major components bolted togehter with 18,395 bolts.
Removed the two cats, and ran into the first problem; the downpipe retaining nut closest to the tranny friction welded itself to the stud.
In fact, two of the up pipe flange studs friction welded while I was removing them for use with the header up pipe.
Had to remove the right side motor mount-to-crossmember nut & raise the engine a tad to remove the up pipe and install the integral up pipe from the header assembly.
During header installation, the 2nd problem happened; I managed to put a "not to deep" 2 inch cut in the palm of my hand.
My daughter was climbing over me, instead of walking around me, and I ended up cutting my hand on one of the metal zip ties that secures the header wrap.
"It was you're fault...you were in my way," daughter yells at me running into the house.
The rest of last night is a little blury, due to blood lose & a few more beers to kill the pain, but I do remember Matt Damon, whiskey, and boobies.
Finished the headers earlier today & fired up the car to ckeck for exhaust leaks and what not.
First impression is that the exhaust note is different; not good/bad, just different.
As the engine was running, causing the header wrap to smoke, my son asked, "What's that?"
Smoke from the wrap, I explained.
"No. Not the smoke. What's that?", he asked while pointing under the car.
Dripping oil.
DRIPPING OIL?!
"SH*T!", I said as I turned off the car.
Inspection revealed that somehow during removal/installation, the lower little semi-circle gasket piece(picture attached below) was damaged & pushed in a bit, causing an oil leak.
Anyone wanna bet that the dealer has to order this item & it'll be a week before it comes in?
03-20-2005, 03:55 PM
#5
Warm Fuzzy Admin
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Ouch, dude.
Tell me which side and which seal it is (Front or back of head.) I'll see if we have anything.
Biggest problem is that the head probably needs to come off to put a new seal in correctly
Tell me which side and which seal it is (Front or back of head.) I'll see if we have anything.
Biggest problem is that the head probably needs to come off to put a new seal in correctly
03-20-2005, 04:11 PM
#7
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Originally Posted by BAN SUVS
Looks like a cam seal for the valve cover. You might get lucky on that one and not have to take the head itself off. Sucks to see though.
Sucks to see though.Yup, I just wanted to get the specific cam it was off of/near. JDM motors have metal plugs, it's nice.
03-20-2005, 04:17 PM
#8
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Paul, that's a pretty typical goof when installing turbos or uppipes. One nick of the wrench and that damn half-moon seal will pop right out. You may be able to re-use the one that came out, but I can't find anything in the STi service manual.
Here's the part# from the WRX and I assume it would be the same for the STi: 11051AA070
It's $4 from subaruparts.com. The description says it's a cylinder head plug.
Here's the link to the pic: http://www.subaruparts.com/diag/?mod...category=006-1
It's the part marked 11051 in the pic:
Here's the part# from the WRX and I assume it would be the same for the STi: 11051AA070
It's $4 from subaruparts.com. The description says it's a cylinder head plug.
Here's the link to the pic: http://www.subaruparts.com/diag/?mod...category=006-1
It's the part marked 11051 in the pic:
Last edited by Egan; 03-20-2005 at 04:19 PM.
03-20-2005, 04:18 PM
#10
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Originally Posted by Egan
Paul, that's a pretty typical goof when installing turbos or uppipes. One nick of the wrench and that damn half-moon seal will pop right out. You may be able to re-use the one that came out, but I can't find anything in the STi service manual.
Here's the part# from the WRX and I assume it would be the same for the STi: 11051AA070
It's $4 from subaruparts.com. The description says it's a cylinder head plug.
Here's the part# from the WRX and I assume it would be the same for the STi: 11051AA070
It's $4 from subaruparts.com. The description says it's a cylinder head plug.
Would be worth a try though for sure.
03-20-2005, 04:23 PM
#11
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After doing a bit of research, you will have to pull the valve cover to replace the cylinder head plug. But at least you don;t have to pull the head. 
But at least you don;t have to pull the head.
03-20-2005, 09:24 PM
#14
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Thanks, Egan, for the lovely picture...that's the part, alright.
JDM motors have metal plugs?!
****ing **** are still pissed about the whole Hiroshima/Nagasaki thing.
The valve cover is off; I removed it, hoping the moon piece was still usable.
I can't reuse the old one as the locating flange portion got chewed up a little by the exhaust cam end.
Cams would be nice, but I can't justify $1k for a few hp.
BTW, what version of the parts manual cd is that picture from? You can PM me if you'd like.
JDM motors have metal plugs?!
****ing **** are still pissed about the whole Hiroshima/Nagasaki thing.
The valve cover is off; I removed it, hoping the moon piece was still usable.
I can't reuse the old one as the locating flange portion got chewed up a little by the exhaust cam end.
Cams would be nice, but I can't justify $1k for a few hp.
BTW, what version of the parts manual cd is that picture from? You can PM me if you'd like.
Last edited by FW Motorsports; 03-20-2005 at 09:26 PM. Reason: i kant speal