el_freddo

Jono, that fella either didn't read and follow the instructions properly or didn't keep the revs up or didn't realise the consequences of not doing it right. Even then, pull heads, unblock valves, new HGs and off you go again. It didn't need to be parted. Anyway, all the best with sorting this issue. It's a bit of a shat-your-dacks situation :/ Cheers Bennie

EJ so worth the effort! once you cut down a loom correctly you realise it's not that hard to do and isn't a huge amount of work that it's made out to be. Your first time is always the most awkward/confusing/nail biting/burn the bloody thing experience... Once enlightened it's easier the second time Good to hear you've got the diff ratio sorted. So it's the RX variant, with alloy wheels, side skirts and ej20? Cheers Bennie

@jono Have a read Previously mentioned article supplied by GD in another thread: http://www.snowvalley.20m.com/bikes/dnthone.htm This is the way I'm going Jono. Saves pulling conrods which saves big end bearing issues amongst other things Cheers Bennie

Aw spoob that's munted good and proper No one in the vehicle when it was hit (I read it as a drunk hit the brat while it was parked)? Glad to see you got yourself a replacement - and a targa too. Now you've got spare glass and other various parts... Not the way to get them though. Cheers Bennie

Yours will most likely be a 1.8 H4 SOHC 8 valve. You can try partsouq.com or parts.subaru.com (or subaru.parts.com - I can never remember which one it is) for parts too. Cheers Bennie

Make sure it's not an L series unit. What you want is one from a brumby/BRAT/MV as these will bolt in and have the sender unit on the rear of the tank. You might find a forum member here that has one available Cheers Bennie

You could be eating a lot of popcorn @Crazyeights! This build will be a slow burn so to speak! Cheers Bennie

Thanks GD! ill have to update how this went once I manage to get this engine together - it's a time issue more than anything. Cheers Bennie

All seals on the r160 are the same size for diff stubs. I'm sure they changed when they went to female fittings for the drive shaft. You shpuldnt have to remove anything other than the driveshaft and seal to replace it. Cheers Bennie

There should be a little black box near the steering column area. This will be an 8 wire plug from memory. This box is the fuel cut out relay if it can't detect ignition pulses from the coil. Either remove it and loop two wires together (can't remember which ones now sorry) to run pump whenever ignition is ON or reace it and hope the second unit is good. Cheers Bennie

Pull the loom. As you unplug things label them! You're after things that are engine related only. Label these as this will make the loom cut down easier. Get a wiring diagram that's model specific as this will help out identifying different wires that either go to the instrument cluster (tacho oil etc) or to other locations such as speed sensor and power wires. to cut it down start at the ECU plugs, remove all tape/conduit and tape together all ECU related wires along their paths. Once this is complete and you've labelled those odd wires you need separate, cut the rest out. This should leave you with only the wiring loom left to run the engine with the ECU. This is a good time to bench test your loom with the engine before you start to wrap it back up again. Have fun with it. I can't wait to get stuck into another one Cheers Bennie

Ok so I've read many times recently on the forum to re-ring with a head gasket replacement. I've read the article provided by GD in another thread about why you don't home to "deglaze" a bore or to bed new rings in. What I'd like to know is the procedure of how to go about re-ringing the engine from the time the pistons are out. Basically in terms of: - What needs to be checked? - How is this checked? - Do you buy standard rings for the given engine and call it a day or is it more technical than this (eg, measuring bore to piston clearances with a wire gauge then work out required ring size from this?) I ask these as I'm about to do this to an engine to get one of my project cars going and want to be clear about how to do this properly. I know @GeneralDisorder,@Gloyale and possibly @idosubaru have done this before - if you have the time to share this information or the way you go about it, I and I'm sure other members, would really appreciate some guidance. Regards Bennie from Down Under

That's not what I want to hear Dave... I'm about to swap my brumby to SPFI. And there's no spare parts over here Cheers Bennie

There could be slight differences but you'll work them out. Cheers Bennie

Probably a 2 or 3mm pin punch I reckon... I still don't know how this is done! Cheers Bennie

First gear is designed to be changed down to when basically stationary. Unless you rev match it won't go into first easily from second while moving. Fresh oil can make a huge difference too, especially if it hasn't been changed in many years. Cheers Bennie

If you do this the circlip will drop into the gearbox. It's not a push in shaft arrangement. This clip is accessible only be splitting the gearbox and using appropriate pliers to remove and install the clip safely. these aren't fun jobs by any means. I once ground the cv cup down to the axle to remove it from said axle. Once this was done the remainder of the pin could be removed. A positive of your situation: it's in the front diff which means you've got solid axles to help guide the pin, not hollow stub axles like the rear diff... Cheers Bennie

@3crows - are you saying that the gearbox let go/broke/has done something stupid? Engine is running ok then, just weighed down by increased friction in the gearbox? Cheers Bennie

Some muppet probably used locktite or similar compound on that bolt. It's right hand thread too - just to be sure you're applying force in the correct direction. All the best with it's removal in one piece! Cheers Bennie

Yes. Ps can be fitted to the brumby crossmember too Cheers Bennie

Definitely service the oil pump. If that fails you kiss your efforts goodbye Very interesting read GD! Cheers Bennie

I'll be going for the turbo gaskets on our EJ251 next. The stock replacement gaskets are leaking coolant externally after 80k km :/ i can't remember the part number used last time around... Cheers Bennie

EJ regulator?? Fuel pump nla - that's a laugh. Cheers Bennie

Ah that satisfying feeling when you finally nail an issue like this one! So, what's next?? Cheers Bennie

That's a big write up! There are some things that are US specific but that write up will give you a general idea of what you're in for Cheers Bennie