Installing a Forged EJ257 in my Subaru Forester

hey guys I'm Sam and we're back here at Angel Tech Automotive so we've got a call from Ben saying that he's got a misfire in cylinder number four Ben went ahead and did some diagnostics work and came to the conclusion after a compression test that cylinder four was down to 20 psi we're missing about 100 psi usually in this situation we're gonna find broken ring lands or Pistons or something of that sort but we won't know until we pull the motor and strip it down unfortunately Sam from Andhra Tech Automotive started disconnecting my engine to pull it out of the car because I believe I've gotten the infamous ring land failure on cylinder number four ring line failures are very common in Subarus a lot of times when you mod them when you run more boost the factory Pistons they just they just weren't built to handle more power the car does have a hundred forty seven thousand miles and it went to Alaska and back so because we're assuming Ben has ring land failure what we're gonna be doing is we're gonna put new forged pistons new Forge rods new bearings we're gonna build everything in-house and he's gonna leave here reliable first step we're gonna go ahead and remove the engine assembly then bit by bit take it apart get the heads off get the studs off get the Pistons out and at that point we can assess everything what's going on inside the engine it was only a matter of time before I got ring line failure I've heard of this happening to so many other Subaru owners so I guess now it's my turn but there's definitely a silver lining because now I get to drop in a forest motor and I won't have to worry about ring land failure ever again gotta give props to Ben for doing the oil changes on time normally when we look inside of an engine we can tell if the owner has been changing oils which is what everybody should be doing and we just got to keep going we got to go further so this is your boxer engine it's different than your traditional v6 or inline 6 or 4 or v4 or anything like that this is a four cylinder engine and it's horizontally opposed and because it's set up this way you've got two heads one on each side and they'll both have to be removed and you'll have your short block left [Music] I did find a lot of oil and the cylinder number four most likely the ring line is gone we'll have to pull the piston out to see exactly how many breaks it has but we're pretty certain now that number four cylinder is is where the issue is [Music] so to get the Pistons out they have access points on the front and in the back once you get the wrist pins out the clips out then the Pistons will come out so we just got the piston out of cylinder number four and Sam everything looks okay everything looks okay what's the deal the problem is not your rings or your piston or cylinder number four we are in the process of tearing the heads down to see what's going on with the valves so like potentially a crack in the head or valve seats leaking something like that about clearance or a valve is bent or something along those lines so we're gonna tear apart the head take a look at it we have to have a part to hook the head and see what's going on there well I'm sorry that we had to tear apart the block because we're just gonna put these Pistons back in now is that how this is gonna work no no we're not going we might as well build there yes we will build it all right well stay tuned so it turns out that my ring lands are actually intact which means the compression leak has to be in the head so we remove the valves to get a closer look [Music] but there's something stuck in because it's even about this one part okay have a good outlet machine shot so the exhaust valve on cylinder number four is trashed right yes so what happened it is melted away on this one single point here probably most likely due to the valve lash tightening up and causing a zero gap in between the cam and the valve itself and when that happens it can't dissipate the heat away enough and they'll start actually melting the valve due to the seat not letting the heat go away so how does this happen is this just like old engine over time yeah yeah so we're gonna replace this with some new valves and do the valve seats and yep cool right on one of the exhaust valves and cylinder number four has burnt up this problem can happen to any engine at any time but it doesn't matter anymore because Andra tech is building me a fully forged engine with new valves and buckets with proper clearances if you want to see them assembling the new engine we've made an ASMR style video of the whole process last week so check that out I'm gonna jump ahead to the short block already being assembled and on to installing the accessories there's something really satisfying about watching an engine block get built from the bare case half's bolt by bolt into something that's starting to look familiar and it's nice to have the peace of mind knowing that every gasket is new and every bolt is freshly torqued [Music] so here we're off building this block you've probably already seen it in the previous video and we did a more kind of ASMR style video on assembling this block but I wanted to take a minute to talk a little bit about what's going into this engine before we put it into the car it's got mainly forged pistons and rods in it so hopefully we're not gonna have any potential ring lamp failure in the future we've done a valid job on it and all that so that the valve issue that it had was taken care of and now we're basically reassembling all the accessories onto the block one of which is the oil pan I'm going with a killer B oil pan because it has a larger capacity in it it's got a thicker flange on it it's got a much more secure oil pickup tube balloon or not oil pickups crack on Subaru blocks stock oil pick ups they're just a little bit thinner they don't have as much brace or support on the oil pickup not only is it thicker it's got a bigger pickup tube so it's gonna actually get the oil sucked up much better and this brace is not going anywhere could be one is gonna give me much more reliability especially if I'm gonna go on the track with this car which I'm probably gonna do at some point so we're gonna put that on there we're gonna put the rest of the accessories on it intake manifold all of that and then we're gonna drop it into the car if you want to see this engine getting assembled in more detail we made an in-depth video last week showing the process we also posted just about everything that we do in real time on our Instagram story so check that out if you want to follow along more closely [Music] Jacob is a master of his craft you can tell the heat builds engines regularly because he assembles my engines so easily that it looks like he's just taking a stroll in the park we put on a new STI oil cooler as well as a stock STI header I decided to keep the boxer Rumble for now but we might change that down the road with something that might make a little bit more power but we have to pause on the engine assembly for now since we're waiting on more parts to arrive okay so we are waiting on some tappets to come in for my engine so until those tablets come here we can't really do anything but I wanted to show you guys kind of the lot of cars outside here at ander Tech because it's really amusing surprisingly a lot of foresters this is mine there's no engine in it right now no engine because it's inside being built we have our interns sell seer super rad right-hand drive my stuff st eyes are everywhere but foresters are also everywhere [Music] one two three four silver oh four oh five Foresters outside here which is crazy but what's really crazy is this one back here this is not your everyday Forster as you can tell by the front mount being larger than my body but and also it's got like archer blades on it and all that kind of stuff but that's not that's not where it stops check this out - jay-z single turbo - jay-z in a forester so maybe I should have done this and maybe I wouldn't have any engine problems if I just put a 2j in it I don't know there's a legacy over here let me show you that looks just like my old legacy it's the same color same year I want to say 2008 what else do we have they don't typically work on other cars other than Subarus but this guy used to have a Subaru and sold it to them now he has the BMW with their nice livery on the side but this thing sounds really good so that's everything outside but inside there's a lot of cool stuff going on as well another Forester up here we got Riyadh working on that STI that just pulled in this is his car it's in progress quite clearly but it's gonna be super rad this is Rob's s2000 and then this blah blah STI right here is used to be the guys that has the BMW but now it's Jacobs the guy that's currently working on my car and he's building it for like 900 horsepower or something like that let me show you upstairs as well there's like a ton of parts upstairs so parks rooms over here at least one of their parts rooms they've got two rooms that have parts but this is like the used parts room so whenever they take stuff off of cars that they don't need or spare stock parts and stuff like that they keep it all here there's like 20 axles their drive shafts there's a pile of suspension over here and then you've got like 25 blocks some of them have already been you can tell been to the machine shop there's a semi closed deck there's a closed deck but I think our tappets are probably back we might have our tappets here I don't know but let's get back to the engine build with the new buckets installed Jacob checks to make sure they're all at the proper clearances now we can finally finish reassembling the new engine some of the accessories going onto the block are brand but we're also reusing a lot of the old engine parts to keep the budget down all right so you might notice that Francine is in a different location than she was earlier in this video and that's because we had a roller outside because we were waiting on parts and they need to move some things around so this is where she is now and obviously still no engine in it we've got Jacob over there assembling the accessories onto the engine and we're about to drop it in probably in a few hours but we're pulling another late-nighter to see if we can get this thing in here today which would be pretty cool with each part that goes onto the engine I get more and more excited with this engine I'm not gonna have to worry about any little things breaking because I know that it was all put together fresh with the exception of some of the accessories that I know are still low mileage everything else is looking very fresh so Jacob how hard is it to put an engine into a Subaru it depends on what modifications are done to it some of them can be kind of difficult but this is stock platform pretty much so it should go in fairly simple without many hiccups yeah we should have this running in about a couple hours maybe two two and a half hours it didn't take long to get the new engine installed them to the Forester honestly superb engines are pretty easy to take in and out of the car now all that's left is to connect up the simple stuff and add one more mod the cob air oil separator basically what it's doing is its routing all of the crankcase pressure and all the excess PCV system through this catch-can causing it to allow the oil to separate from the air before it goes back into the intake tract and it drains it back into the block through the top for it yeah these are these two our coolant lines coming out right now it heats the can up try to help the moisture separate from the air and dissipate it there's two lines that will come up and they go right to these two side ports right here and then there's another port that comes off the top of the block that will go right to this bigger port and then the drain goes to the same port just on the other side of the tee and comes up under the catch can where you really can't see it right now and that is what allows the oil to drain back into the block this is it we're on the last few steps now we're just buttoning up the engine with the final pieces and then we'll be ready to start the engine for the first time well that is after we primed the system first basically we'll leave the plugs out of out of the car and crank it over so it doesn't build compression and it'll actually build oil pressure while cranking it over with the OEM starter [Music] after they primed the system they looked over the engine for any leaks before we fire it up we want to make sure that all of the gaskets were seated properly and after a thorough inspection it's time to fire up the engine [Music] [Applause] and ER Tech has a break-in procedure of 1,000 miles which means I can't drive this car car or a attend I know until after minute gingerly for 1,000 miles but I can tell you already that this engine feels fantastic and I'm stoked for the new stronger power land [Music]

Channel: Gears and Gasoline

Views: 418,340

Keywords: Subaru, Engine, Build, Assembly, Forged, EJ257, boxer, motor, ej25, forester, xt, sti, built

Id: bVP_M90OJFc

Length: 14min 18sec (858 seconds)

Published: Sat Mar 23 2019