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Old and New Subaru boxer short blocks

A mechanic at P & L Motorsports in Franklin Park, Illinois explains the short block engine swap in my 2005 Subaru Outback.


 


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7-Bolt Shortblock Failure - Full Diagnosis
If you are your own mechanic, there is no more important character trait worthy of development than the ability to own your mistakes. That's where the line is drawn between good mechanics and bad mechanics. It's not the failures but how they deal with them that measures their ability. In short, it's not easy to admit you did something wrong or were negligent. But if you don't own it and talk about it, it doesn't get fixed, and nothing positive can come from it. It was my quest to overcome my clutch issue that lead to the creation of a video. That video is the textbook perfect guide for how to correctly install a DSM transmission. https://www.youtube.com/watch?v=6bE_9sWtnSY&list=PL4B97C16D423317DD Crankwalk as described is caused by a casting defect. This was not a defect. This was preventable. A lot of people would find something like this and not tell anyone out of embarrassment. I'm not ashamed. It's my fault. I got good use out of this engine and it was tough enough to make it 48K miles since the last rebuild despite my abuse. I'm here to tell you if you bought a used car that's had its clutch replaced, or if you ever pay someone else to do it... make sure it has this bolt. It's stashed away between the starter and the transfer case, so it's hard to see. Make sure all of your bell housing bolts are torqued properly because fastener problems can destroy your shortblock, clutch and transmission. If your car fails because of a mis-aligned transmission, you have no reason to blame crankwalk. It wasn't until I bought my next AWD car that I discovered there was a smaller bolt on the other side of the block. I destroyed 3 transmissions in the GSX first. With the damage already done to my crankshaft, I then lost a shortblock. It's an ounce of prevention that's worth metric tons on your bank account. Grade 10 M8x60 bell housing bolt = MD706012. It gets 22-25'lbs of torque. Owning my mistake permits me to learn from it through con$equence$, and never repeat it. What good would it have done anyone else for me to learn this lesson and not share it? That's why I'm providing this video to all of you. Sharing it can perhaps help someone else avoid this costly mistake. This is the final chapter for my 7-bolt, and this book is going back on the shelf. Here are some valuable resources if you're trying to read bearing damage: http://www.enginebuildermag.com/Article/5150/csi_engine_bearings_when_good_ bearings_go_bad.aspx http://catalog.mahleclevite.com/bearing/ http://www.studebaker-info.org/tech/Bearings/CL77-3-402.pdf And of course, now that I've covered the complete oil system, transmission and driveshaft series of videos, you now have all the tools necessary to ensure your 4g63 lasts a very long time. Whether the casting defect exists?... or it's all caused by a bolt, or the harmonics, or whatever... Sure, crankwalk exists and it's horrible. But with the small amount of movement required for your crankshaft before it contacts the block isn't far enough to make your clutch drop to the floor when you turn. You'd be hearing woodpeckers and jackhammers on the crank long before that clutch pedal would fall to the floor. Some people are going to hate on me for saying that. That's fine. I believe all of the people who experienced the clutch pedal issues had fastener problems on their bell housing. DSMs get a bad reputation for this but we can change that. Crankwalk is never the cause of your engine failure. Crankwalk is always a symptom of the real problem. It's your disease that makes you deny it's your fault. You've got the 'itis. DSM-itis. Whenever you dig deeper, you'll discover what applied all of those thrust loads to your crankshaft to begin with, and it's not going to be a casting defect that moves your crank .101". Mine only went .014", but all of the same parts failed. PLEASE tell me in the comments if you find this bolt is missing from your car.





Learn About Subaru Boxer Engine Technology
The Boxer Engine is a Subaru Core Technology. Learn about its benefits and advantages. Web: http://www.newroads.ca/blog/tag/subaru-technology/ Visit us online: http://www.newroads.ca/subaru Twitter: https://twitter.com/SubaruRH Facebook: https://www.facebook.com/RichmondHillSubaru Pinterest: http://pinterest.com/richhillsubaru/ Stop in and say hi at 11645 Yonge St., Richmond Hill, Ontario Toll Free: 1.888.306.4960





Cylinder head rebuild EJ25D
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Hyundai Elantra 4g63 Shortblock Assembly
HOLD ON TIGHT! HERE WE GO! We begin the blueprint and assembly on my 1992 Hyundai Elantra's bastardized 4g63. The parts used in this are from a mash of different brands and models outside of the typical 2.0L 4g63, but the specs and standards I am following for its assembly are for the 2.0L DOHC. If you want to follow along in your service manual to verify what I've done here in this video, the processes we cover here detail pages 11C-95 through 11C-105 of the 1g Overhaul manual. I would prefer you not rip them from the binding and throw them away, relying only on this video for instruction... but rather use this video as a motivational guide, and as a demonstration of the techniques involved in those sections. You gotta do the cooking by the book. I never had any intention of making instructional videos on this particular car, but after it blew up I slowly realized it's actually a better case study for how a 4g63 ticks than anything else in my driveway. There are several reasons for this. One being that it's a mix of parts that shouldn't be bolted together, and the other is that many of you watching my videos aren't trying to build a 600hp engine out of aftermarket parts. You're trying to put back together what used to be your daily driver. This car covers those bases. Don't think for a second I won't go through this same trouble and level of detail for the GSX. I will. When I do, having this information in this video will give you a better understanding on how and why I do things the way I do when I get there. This was the shortest I could condense this video. I've never uploaded a video this long, and I hope I never have to do it again. It took a month to create on cutting-edge equipment, 16 hours to export, and 9 hours for YouTube to process. My script for the voiceover is 6 times longer than the whole script for the movie Pootie Tang. 6 times. Longer. Than a Hollywood movie.





Project Import: JE Pistons 291060 for EJ25 block w/ EJ20 heads
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Subaru Short Block Benefits
Mark Sadowski of P&L Motorsports, 3847 Carnation St., Franklin Park, IL 60131, discusses the benefits of replacing a blown 2005 Subaru Motor with an OEM shortblock, and the procedures involved in performing the engine swap.





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1972 vw bug with subaru engine conversion, watercooled. more horsepower and more reliability equals one great conversion.





The Worlds best car tuning disasters and engine failures II - Caught on tape
Wow its tuning disaster II Time More of the webs greatest tuning and high performance engine failures -- you can push and you can push your tuning, but sooner or later some things gonna blow Top 30 all-time tuning failures - close your eyes and watch through your fingers this is very scary stuff, more breaking engines and bank balances. www.viezu.com ECU remapping and car tuning at its best. Car tuning training, software, tools and equipment. Whatever your tuning needs we are here to help. Insured, guaranteed and custom tuning for over 3000 different vehicles, tuning for power, performance, fuel economy, motorsport and carbon reduction -- Tune with the best and mail us at info@viezu.com. For all car tuning training, ecu remapping and car tuning courses and classes see our technical academy www.remap101.com





2005 Subaru Outback Engine Replacement
This is my 2005 Subaru Outback with the old engine removed. I'm talking to a mechanic at P & L Motorsports in Franklin Park, Illinois about the procedure to replace my ruined motor with a new short block and rebuilt heads.





Fiat 500 with Subaru engine
See: http://www.zcars.org.uk This is a Fiat 500 modified by ZCars Ltd to the specification of a customer from Greece. The design brief was to fix his 500 in an interesting way so that it would have more useable power to enable him to drive his family around town in comfort. Whilst he was tempted to have the Suzuki Hayabusa conversion ZCars also produce he decided that he wanted to keep the rear seats. As that is where the 200bhp motorcycle would be installed that option was ruled out! The engine is an EA81 Subaru engine (1800cc flat 4) which is quite an old engine although still widely used as an aviation engine we are told. This engine was used due to its simplicity, power and torque characteristics and not least its size and shape. This was mated to the original gearbox with clutch and drive shafts up rated. Also up-rated were the brakes with discs all around and the suspension at the front. The transverse leaf spring was removed and adjustable alloy dampers were used with coil springs. A new front subframe was fitted to allow the use of wishbone suspension arms. Obviously as it is a water cooled engine, radiators were required. This was inserted into the front boot space (trunk) and water pipes run underneath the car. A new stainless steel Exhaust finished the conversion and new wheels and tyres were fitted as an optional extra.




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