4 days to do engine swap

Willie · Post by **Willie** » Mon Jun 12, 2006 3:50 pm

I have the next 4 days off to try and get the engine swap in my RX Touring Wagon done (EA82T - EA82T).

Should be do-able; am awaiting new clutch kit from Steve at Rising Sun, which should be here next day or so. Then when old motor out, flywheel and all 4 discs will be sent in for machining. Swap over a few parts, (dizzy, injectors, inlet piping for IC etc) and the normal swearing at things when they don't quite fit, or I don't remember where they go!

Biggest possible obstacle will be the kids - both have been sick all last week, and cannot go back to school and daycare before they (sorry - no nice way of putting this) have solid poos. If either needs to stay home, very little will get done. (Wife's away in Townsville this week).

Anyway, wish me luck. Will post during the week if I get stuck or maybe post some pics of the skinned knuckles.

Stay tuned for results when I get it all going.

Lapsed · Post by **Lapsed** » Mon Jun 12, 2006 6:31 pm

good luck with it. hope that you do not loose too much skin on the knuckles

D3V1L · Post by **D3V1L** » Mon Jun 12, 2006 8:18 pm

hahha. well said lapsed......good luck mate.....make sure u put a few pics on here because im going to be doing a similar job soona s well....would b interrested in what will/will not go wrong

steptoe · Post by **steptoe** » Mon Jun 12, 2006 9:09 pm

don't remember where things go ?

I use a cheapo digital camera and just go mad...click,click

Nice smile ! Look away, yeah , that's good baby !

Yeah...now,, just another angle of the same stuff and without the flash !!

I go the anal approach (not the dirt road !) and list each move in a folder, & use little Glad brand zip lock bags and label them, sometimes number them, stack them in order of job. Screw all bolts back in their holes so they are there when you need them again.

Plenty of rags and dishes for fluids...like I said, anal approach

keep us posted

And I might race you . Planning to get motor out Tuesday before 1pm, but then again I was gonna get it out today too !!i

PeeJay · Post by **PeeJay** » Mon Jun 12, 2006 9:40 pm

I managed to pull my engine, fix the flywheel, change my gearbox to 1.5 low and put the whole lot back again in 4 days earlier this year. Could have done it quicker if I worked more than 5 hrs a day

Willie · Post by **Willie** » Wed Jun 14, 2006 8:54 pm

Quick update ........

Clutch arrived - thanks Steve! (Rising Sun - SA)

Swapped all injectors, fuel lines, vacuum lines and wiring so as all connections fit etc. These Jap import motors normally arrive with lines / wires cut and the little alloy vacuum pipes bent. 2nd time bought a jap import - both times the same!

Distributor doesn't fit

Old motor has casting that dizzy bolts to - new motor has plate to secure dizzy - mounting bolts not quite the same - looking at options now. ( Could either swap rocker boxes between motors, or maching new slot in dizzy base plate.)

Flywheel machined and new clutch all fitted - no clutch alligning tool, so sockets and extensions used to improvise.

All ready to go back in now - however have a specialist appointment tomorrow morning and wont be back until after lunch. Will sort out dizzy first, then straight back in ( where's the emoticon for wishful thinking?).

Then all discs will be machined, exhaust sorted (hits in about 3 places) and off across the pits - not sure on how NT sees these conversions and lifts, however plenty of other makes with lifts and engine swaps (V8s into landcruisers, etc)

Will update again soon.

Cheers

steve_rising_sun · Post by **steve_rising_sun** » Wed Jun 14, 2006 9:30 pm

Willie, ring me re dissy
Steve

BlackMale · Post by **BlackMale** » Thu Jun 15, 2006 10:21 am

Sound like she is coming along nicely. Look forward to the catch up once she is finished (as you have mail

)

Willie · Post by **Willie** » Thu Jun 15, 2006 8:49 pm

Motor's in.

Dizzy problem fixed - now only held in with one bolt.

Took a couple of goes to get clutch aligned correctly.

Tomorrow will see everything geting put back on, bolted up, ancillaries fitted etc. Must remember to add oil and water 8O

Then the start up ...... can't wait.

Forester goes in for 12,500 km service in morning, then back home to get into it.

Stay tuned .............

Suby Wan Kenobi · Post by **Suby Wan Kenobi** » Thu Jun 15, 2006 10:48 pm

Having forgot to fill the diff oil in a car once as i thought i would do it in the morning the best way to not forget is to use an A4 paper sleeve and put the key in it with Check oil written on it and have it hanging over the wheel. If you forget then you need help.

Good luck with it all.

steptoe · Post by **steptoe** » Thu Jun 15, 2006 11:21 pm

I'll be careful before I race anyone next time. I have the fan shroud and sump guard removed and 30mm of ice on top of the water barrel !

The tools are far to cold as is the shed !
Was talkin' to a Darwinite today who was suffering sunburn after a mission on the water up there in recent days . What a contrast in temperatures !

Yeah, and remember all the earth straps before cranking, I've found they help.

D3V1L · Post by **D3V1L** » Thu Jun 15, 2006 11:54 pm

jono wrote: Yeah, and remember all the earth straps before cranking, I've found they help.

hahaha...i too have made that mistake...and it took quite some time to work out what was wrong....talk about...um.....slow

Willie · Post by **Willie** » Sat Jun 17, 2006 8:58 pm

Latest instalment ......

Got everything in and bolted up, as previously mentioned. Filled oil and water, did final checks and then the big moment arrived................ Damn thing wouldn't start, though

Checked spark and fuel - all seemed OK.

After much toiling and another phone call to Steve (poor bloke, I've pulled him away from work about 3 hours this week!) deceided the timing was 180 degrees out - ran out of time to check though, as I had to pick up Forester from it's service and then pick up kids from school / daycare. Was running late, so bike ride to Subaru dealership was done in record time - not sure if they appreciated sweating, puffing customer in their new pristine service lounge.

Once the 15 month old son was down for his morning nap this morning (Sat - wife not back until 2 pm, then back to Townsville again Mon for the week) , put on the work clothes and rotated motor one cycle to the timing marks and pulled out dizzy, replacing it pointing to #1. Fingers crossed and .........

started like it was only running ten minutes ago.

Idling at 2000 rpm - throttle cable too tight - and clutch way out of adjustment. Just little things, so should get them sorted next time I have some spare time.

Next on the agenda is rebuild brakes (well, machine the discs and put in new pads) and try and get this exhaust to not touch anything - hitting in about three places at present.

Then it's off to the transport dept and over the pits.

Anyway, that's all for now. Thanks for tuning in for another episode of Willie's Subaru Stress.

Tune in again for the next instalment to see if I get this girl on the road.

Cheers,

steptoe · Post by **steptoe** » Sun Jun 18, 2006 6:47 pm

The old '180 degrees' trick gets ya every time doesn't it ?

I have the same problem with my exhaust and it is another thing I can't wait to fix. Would not have happened if a fork lift was left in the corner when it came time to move it in the 'storage facility' spit....

good luck at the pits !

Crown lager in back seat maybe ?

Willie · Post by **Willie** » Thu Jun 22, 2006 4:59 pm

Nothing happened since last instalment - I'm back at work and wife away in Townsville. She'll be back this evening.

Father in law arrives Sunday, so I'm sure Saturday I will be cleaning up around the house, and anything else I'm told to do

Have 3 weeks off soon, with first ten days at Daydream Island. No work, no subaru, no neighbours ......... can't wait.

When we get back I hope to get plenty of work done on the Subi, however it is school holidays and I will need to spend time with our 6 yo daughter. The 15 month old son will probably go to daycare for the majority of that time, though, so I'll be able to get to it regularly (I hope).

I am spending alot of time away in the second half of the year, so I need to get this finished sooner rather than later.

Anyway, stay tuned for another update in a couple of weeks.

Cheers,

steptoe · Post by **steptoe** » Thu Jun 22, 2006 10:24 pm

size 6 overalls, coming right up !

Willie · Post by **Willie** » Tue Jul 18, 2006 9:43 pm

Thought I should post an update ....

Back from our holiday and have a few days off before going back to work next week - so try and get this wagon finished and registered

Clutch is working well - might adjust a bit more for a better feel. Idling far too high still - can't work this one out - have posted topic in troubleshooting on this, brakes and diff mount.

Brakes are terrible - not sure whats going on here, either. I'm thinking booster ???????

The motor runs well and sound good. All electrics are working, so I obviously connected everything back together correctly.

I'm worried the MVR might knock it back for rear lights being obscured by the spare wheel carrier and jerry can carrier on the rear bar. Have priced some LED ancillary lights just in case, but will not buy until it gets knocked back - they're not cheap!

Got my Ausubaru stickers in the mail yesterday, so they will go on soon to really complete the car!

Anyway, hopefully will get the brakes and idling sorted out and get this thing over the pits and registered. Will post another update soon.

Regards,

Soobeit · Post by **Soobeit** » Tue Jul 18, 2006 9:58 pm

Good to see you are back and straight back into the wagon, I must come and see your rig before you go back to work. My ute is going well but I think I have to adjust the valve clearence as there is a bit of ticker comeing from the number 4, I will be out at work tmrw to get new ID and to do a few odd jobs that has to be done out there. what are you up to tmrw? If you are free tmrw I might drop around. So how was your holidays in Qld? Im off down that way in a couple of weeks for a break, should be great. So need a get away at the moment.

Willie · Post by **Willie** » Tue Jul 18, 2006 10:30 pm

Hey Soobeit,

Feel free to drop around - give me a call first ( 0413 245060 ) as I need to pop into town to pick up my mountain bike sometime.

See ya,

Soobeit · Post by **Soobeit** » Tue Jul 18, 2006 11:03 pm

no worries, If I have time I will give you a buzz on your mobile.