Project: AWD TURBO Family Hauler (04 Forester 2.5XT)

[WRXtranceformed]

Well done dude! That is a lot of work. I don't miss working on that engine bay, boof

[DavidL]

Nice work!

Fingers crossed that the IC install is easier than most of my previous attempts... although I think the aftermarket hoses you use will help. I distinctly remember a couple hours spent with 6 arms and a variety of strange tools used trying to slip all those hoses back in their requisite places at once.

[JustinG]

So got the coolant line crush washers from Subaru of Richmond after a few meetings today. I was able to jump in the garage at 4:30 and get to work.

Walked into the garage and moved the td04 outta the way to find this.....




Its leakin earllllll....I'd say it was a bad seal.

So all I really had to do was bolt up the coolant lines, which was easy enough.
And slap the downpipe and new gasket back on. Tq to 26 ft lbs, and reinstall the heatshield.

Easy peasy, there is a freshly installed vf39 ladies and gents.


Next was the STi tmic.

Wrapped the a/c lines in some fueal hose cause they may get some heavy petting from the IC with normal engine movement.


After trying 5-6 times to install the IC i realized the turbo elbow was too long, so i trimmed that down. It is also way easier to install if you remove yhe driver side IC bracket.

Fully installed STi TMIC.


Topped off the coolant, after losing about a gallon from the turbo lines....since they decided to act as a siphon.

Pulled the IGN fuse to prime the turbo with oil, instead of spinning a dry turbo at 50,000rpm. Pull fuse crank for 15 sec - stop - crank for 15 again. Oil loght goes off no issues there.

Check for oil leaks nada.

8PM, say goodnight to the offspring and bavk in the garage.

Load VF39 map, crank up car, monitor coolant levels and top off.

Enter the smoke show!

So when I pulled the turbo a good amount of coolant got into the dp and uppipe, so it smoked from the exhaust......alot. Also a good amount of smoke from under the hood from all the coolant spilled onto the exhaust and all the crud burning from the stored in a box turbo.

After idling and revving for 20min or so it finally stopped from the exhaust and the exhaust tip was very wet with condensation (TWSS) initially. But the smoke finally stopped and the exhaust tip was dry.

Under hood smoked slowed significantly, source seemed to be from the headers and uppipe.

My fingers are crossed that all the smoke is from removal and new install and not my fuck up.

Can't test drive it because they are doing a road block/dui checkpoint in front of my house, and although I've only had 3/4 of a mich ultra, I ain't chancing it.

I may drive to work tomorrow, or wait and drive it when I get home, just incase there is an issue and im not late for work.

Anyways, initial impressions will have to wait til tomorrow, but it idled and revved fine, just have to make sure this is all residual smoke from the install and no boost leaks.

[JPolen01]

DUI check point on a Monday?

[D_Eclipse9916]

DUI check point on a Monday?

Because Richmond... :lol:

Great progress! I am sure its just residue burning off. Even if you just touch an exhaust component with your hands that have oil/grease/coolant it will smoke. So imagine touching a turbo/uppipe/downpipe etc with all the oil lines/coolant lines back there.

With all of the decent hardware being acquired, this should be a good car show this year.

[Beej]

Ha, it'd kill me to wait another day to drive it. Fingers crossed for ya, though I'm not sure we'll race after this one.

If the turbo really was the cause of all this, I can't imagine a better scenario/excuse for a cheap and significant upgrade. That's awesome.

[JustinG]

DUI check point on a Monday?

We so hood.....

[JustinG]

Nice work!

Fingers crossed that the IC install is easier than most of my previous attempts... although I think the aftermarket hoses you use will help. I distinctly remember a couple hours spent with 6 arms and a variety of strange tools used trying to slip all those hoses back in their requisite places at once.

It was a pain in the D, until the realized the Samco elbow that goes from the IC to the turbo was too long. I trimmed about an inch off and it was still about 1/4in long but worked. After trimming it, it popped right on.

[ScottyB]

awwww yiisssssss

looks great man. i love "realistic" upgrade paths as well because i know you'll be able to enjoy that power so often. really excited to hear how you like it. how was working on the turbo compared to your old DSM?

[JustinG]

Both had their challenges, DSM everything was up front relatively easy to get to but in a cramped space, basically have to drain the coolant and pull the radiator to have enough room and work safely without punching a hole in your radiator. With the XT if you remove the TMIC you have a crap ton of space to work with its just at a horrible angle.

I like the simple mods, everything is OEM so it just fits. The parts that weren't OEM, the Samco hoses and AVO turbo inlet, gave me grief and took up the majority of my time trying to install/make them fit as designed.

[JPolen01]

Samco hoses are a nightmare!!! I helped install one on a 07 sti and it was such a pain in the ass.

[JustinG]

So took it for a 30 minute spin after work.

At no point and time did it burst into flames. Coolant temp stayed normal. Vac was in the right range. Smoke was non existent under the hood, and no smoke from the exhaust. No leaks. I think my problem is solved.

Initial impression........HOOOOLLLYYYYY FFFFF.

Tis quick, It kinda scared me when I stomped on the gas, I wasn't expecting the power that happened. I didn't realize how bad the turbo was, compared to the VF39 the td04 spooled up about as fast as a dyno queen supra. The td04 was only hitting approx 11 of the 14 psi it was supposed to be hitting. The vf39 hit 17.6 psi, it should only hit 16.5 but it tapered off closer to red line as expected. I think running a catless DP and the turbo inlet could be causing the 1-2psi boost spike. No instances of knock reported though during these spikes.

I'm still nervous and freaked out that tomorrow it will burst into flames or the smoke will return, cause I am just that way.

But so far.....

[JustinG]

Made it to work, I think the AP has sorted itself out. Never peaked past 16.7psi. Car didn't burn to the ground on the way to work. Just condensation this morning, no smoke. I am not saying it is a success yet......but the issue seems to be resolved.

[V1GiLaNtE]

Nice work Justin. Glad to see you saved this one without spending a fuckton.

[JustinG]

Yea, had I not been like....well I should upgrade this too, and just done a td04 replacement, it would have been like $200.

[SlimKlim]

Nice!

How much power do you think you make now?

[JustinG]

Nice!

How much power do you think you make now?

I have seen #s all over the place from 260whp up to 290whp

Looking at similar mods/mileage of other cars I am thinking a safe guess would be 275-280whp with the "Off the Shelf" Stage 3 tune.

Most of the guys with close to 300 have a Pro Access Port tune.

I'm tempted to do a pro tune, but $500 is a lot of money when the OTS tune works just fine. Subaru people always bitch about the OTS tune, but there is no knock, and it runs fine. I think I am ok with the 15 less HP I would get with a pro tune and will keep my $500. I could do an eTune, but that just seems overly sketchy to me, when a/f can't be monitored like on a dyno.

[ScottyB]

as long as its not knocking you're fine. those EJ ringlands don't suffer knock well.

$500 can pick you up a fine set of used rally tires

[SlimKlim]

Nice! Similar torque figures or would those be higher?

I've spooked myself a couple times in the VW after having it tuned, I spend 98% of my commuting time hypermiling in moderate-to-heavy traffic on 35mph roads, so when the rare opportunity presents itself, 270-280ft-lbs feels like a lot.

(Shut up DJ, my yardstick is an OBD-I M3 with long tubes that probably makes 200ft-lbs on a good day)

Considering that my FWD+all-seasons render 1st and 2nd gear mostly useless, I can only imagine how awesome similar power figures feel in a car that can actually put it down from a stop.

[JustinG]

Yea torque figures would be pretty much the same as HP