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#1 2012-04-14 00:46:37

Moto
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From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

New guy from North Dakota (currently the the edge of MN)

Tried to rescue an Aero from salty Detroit.  102k miles... Everything is stock.

Power steering crapped out on the drive back, but once I get the part all will be well. (I think the pump is OK, but the problem may be bigger than expected)

Images should appear here as I work through the problems/maintenance.
http://www.facebook.com/media/set/?set= … 6611267aa9

Done so far.
- got a new tire shaved and replaced -> nail on the drive back from Detroit.
- got the little elbow loose on the power steering(not as easy as it sounds) -> waiting on a part from e-bay (USPS's is currently 2 days over due.  Seller has been easy to deal with)
- I have started to deal with the rust under the car, but some of that will be left alone for now. (rust bullet and back paint)

Projects planned (over the next 4k miles)
- There is a small amount of rust on the driver side front pillar that I don't want to spread.  I will likely grind/treat/repaint the affected area within the next week.  (Thinking about leaving it for awhile)
- Timing belt and affiliated bearings/pulleys (all the other recommended stuff on the affiliated post on this site)
- Plugs (maybe plug wires)
- Front and Rear Diff fluid

Possible projects.
- Identify potential points of failure due to corrosion and preemptively start replacing things. (mostly cooling lines power steering lines ect...)

I will probably try to follow this forum now, but I already spend too much time on car websites smile


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#2 2012-04-14 01:07:50

thebillsman
@villadelph
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From: Philadelphia
Registered: 2010-03-30
User Number: 4417
Posts: 4486

Re: New guy from North Dakota (currently the the edge of MN)

welcome to the forum. how much did it cost ya?


05 Aero Limited | VF34

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#3 2012-04-14 01:21:09

Bryan
why don't you remember my name?
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From: Western WI
Registered: 2007-01-14
User Number: 1768
Posts: 10240

Re: New guy from North Dakota (currently the the edge of MN)

IIRC, you can't just do wires without changing the entire coil pack.


I'm cold, and there are wolves after me.

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#4 2012-04-14 07:54:41

krazykarguy
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Re: New guy from North Dakota (currently the the edge of MN)

If you own a Pro5, you definitely know rust. Welcome to the site, and good luck!


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic - 475hp of crowd munching fun

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#5 2012-04-14 22:25:09

Moto
Member
From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

thebillsman wrote:

welcome to the forum. how much did it cost ya?

9.5k with a set of snow tires on separate wheels.
I did get the car from my cousin and I paid what I figured was fair given the amount of work I will have to put into it.  I had been shopping for a WRX for quite awhile, but I decided the is almost no hope of buying a used WRX that doesn't have serious trouble.

Bryan wrote:

IIRC, you can't just do wires without changing the entire coil pack.

Good to know .  I would have done some reading before I took a crack at it.

krazykarguy wrote:

If you own a Pro5, you definitely know rust. Welcome to the site, and good luck!

True, but nothing like what I will have to deal with on the saab.  Most of the miles on the protege were in ND and we don't use salt so there is only minor body corrosion around the rear fenders which I plan to deal with soon.

Cousin drove in Detroit traffic for 5 years so saltwater spray was making it in through the hood scoop and killed a bunch of  lines. 

First real question: (I will go to Subaru on Monday if I cant get it figured out)
Salt is bad...unamused
I was wondering what part this is. (Yes I know I should learn to read diagrams)  I had to cut the end off to get a 6 sided impact driver on it.  Without it I don't think I would have been able to get it off.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/385581_10100199466714195_29403118_42015058_233950317_n.jpg

It came from here
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/529965_10100199443121475_29403118_42014812_493051873_n.jpg


I was thinking it is number 20 on the third diagram down, but I'm not sure.
http://parts.subarupartswarehouse.com/p … n=STEERING
Any input would be appreciated.

I already ordered the whole assembly off e-bay for 25 bucks only to have the guy send me the power steering lines only. facepalm  (Not what was in the photo)
http://i.ebayimg.com/t/B96-04-07-SUBARU-IMPREZA-WRX-STI-POWER-STEERING-LINES-OEM-DIRECT-FIT-TUBING-/00/s/MTIwMFgxNjAw/$%28KGrHqJHJE%21E88,mLmD4BPZ--556yw%7E%7E60_58.JPG
I need the one with the nut in the lower right corner of the picture, but I have no idea what it is called or what the part number is.


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#6 2012-04-15 09:32:36

krazykarguy
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Re: New guy from North Dakota (currently the the edge of MN)

You want part #1 in this diagram:

http://static.opposedforces.com/epc_img/371494934708.png

http://opposedforces.com/parts/impreza/ … tration_5/  (link)

Subaru part # 34190-FE050 Repair kit - pipe  (this will get you both pipes, not just the bad one. It's your call as to whether you split the set and replace just the broken one).


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic - 475hp of crowd munching fun

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#7 2012-04-15 12:18:51

Moto
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From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

Thank you. 
The only way that is the part is if it includes the rubber portion of the lines(It must).  Location wise it looks correct, and the description matches.   

At this point I will probably just got to Subaru and see if they have anything laying around, and have them verify that it is the correct part. 
http://parts.subarupartswarehouse.com/p … am=7591342 The individual component is sold for ~ $50  #23

I think the local junk yard is closed today or I would be scrounging around out there instead of sitting on the computer. smile


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#8 2012-04-15 13:54:24

krazykarguy
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Re: New guy from North Dakota (currently the the edge of MN)

Make sure to check the price on the single hose vs. the "repair kit". I have found that sometimes the kits are more commonly used and hence, cheaper.

Makes no sense, but it's been known to happen...


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic - 475hp of crowd munching fun

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#9 2012-04-19 23:04:47

Moto
Member
From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

Thank you for the help. The Saabaru lives again.  banana  It was about 70 bucks with tax for the whole kit directly from Subaru.  Even the parts guy in the service department wasn't 100% sure when we ordered the part because it doesn't show any of the rubber portions of the line, and he has never seen one fail.

Last edited by Moto (2012-04-19 23:10:05)


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#10 2012-04-20 09:42:38

krazykarguy
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Re: New guy from North Dakota (currently the the edge of MN)

Every time I get Subaru OEM parts over the counter, I always get the "I can't guarantee these parts will fit your car" look/speech.  unamused

I stopped telling them I had a 9-2x.


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic - 475hp of crowd munching fun

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#11 2012-05-06 23:50:48

Moto
Member
From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

Shelled out about 700 bucks for parts today...

Probably going to have to plan a weekend worth of work in the near future.

Timing Belt Kit    $340 (I know I could have saved a little money buying part by part but I was too lazy)
http://www.ebay.com/itm/2002-2007-Subar … mp;vxp=mtr

Light Weight Pulley    $135 (old one is really rusted out to the point that I think the balance could be an issue as the rust is not symmetric.)
http://www.cobbtuning.com/Subaru-Lightw … 300102.htm

Radiator    $127    (after a lot of reading I decided it wouldn't be a dumb idea to replace this very common point of failure)   
http://www.ebay.com/itm/WRX-STI-02-07-D … mp;vxp=mtr

Radiator Hose Kit    $75 (blue might look dumb i'll let you know)
http://www.ebay.com/itm/2000-2007-Subar … mp;vxp=mtr

Plan on doing plugs at the same time
~$45

Just ordered a set of saabaru badges  $40

I'm sure I'll crack 800 before I get all the required things done.  Front and read diff fluid are also on my list.  ~50 for the front.  not sure on the rear.


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#12 2012-05-06 23:56:05

Moto
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From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

I may also delete the stock intake silencer while I have everything apart, but I haven't found any great ways to make an elbow yet.  I'm not a huge fan of cutting the old one apart, and the cheep elbow does not appear to be available any more. I found one for $200 which is a total joke.  I will probably just try to figure out a way to make one.  If anyone has any good ideas please feel free to point me in the right direction.


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#13 2012-05-10 01:49:15

n/aisweak
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From: Mt.Vernon, IN / Afghan
Registered: 2011-01-16
User Number: 5149
Posts: 128

Re: New guy from North Dakota (currently the the edge of MN)

Mach v / fastwrx.com, they're like 45 IIRC.


2006 9-2x Aero 4EAT: ID1000's, Perrin turbo inlet, VF43, 08 STI TMIC, GS Crossover, Titek UP, Cobb TBE, Cobb Pulley, Cobb springs, SPT intake, SPT strut bars, Enkei RPF-01 GOLDIES ..... tuned to 20PSI, E85 map coming!

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#14 2012-05-10 07:27:56

Moto
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From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

Thinking they don't have it any more.  I cant find it anyway... It isn't in the intake section that I see.  banghead


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#15 2012-06-04 23:54:17

Moto
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From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

Updates:  Things are moving along.
Front passenger tire replaced with shaved tired to match

Oil change ~102K Mobil1 full synthetic extended performance

Power steering line repaired (took about 2 weeks to get the right parts)
    * Rust bullet coat on many of the underbody parts
    * Painted the front snow tires
    * Front brake calipers painted with rust bullet

Plugs changed  (~May 5)

Driver side pillar painted (May 12-13, 2012)
    * Buffed and waxed car.
    * Rear snow tires painted.  Prepped with self etching primer
    * Discovered metal under front bumper could use a little TLC.

Rear diff fluid change (Amsoil severe gear May 16, 2012)
- unsuccessful storm chase in northern minnesota. 17th

Front diff/manual gearbox fluid changed (Amsoil severe gear May 18-19, 2012)
    * Pulled intercooler and prepped/painted lines for heater
    * Replaced coolant lines that require the intercooler to be pulled
        - Line from turbo leaked replaced with old line
    * Drained a small amount of oil from engine as it was slightly overfilled
           - Appears that leaky drain plug on oil pan is repaired.  Gasket reseated on oil pan.  It might still be leaking but it is much slower.

Timing belt kit (June 2-3) ~104K miles
    * Kit went in without a problem

           - Skipped the crankshaft seals and oil pump seal as they seemed very difficult.

           - Two of the four idler pulleys  were starting to go bad.

           - During disassembly discovered I need to replace the tensioner on the A/C.

* Cobb pulley

           -Easy install putting things back in after changing timing belt

* Radiator

           - Seems good instal wasn’t too bad, but I did have to shorten the bottom main radiator hose because it was trying to kink.  The shortened hose should not be able to kink, but is not perfect.

           - Also needed to get some metric bolts that were not included with the radiator.

Tensioner pulley for A/C belt. (June 4, 2012)
           - New tensioner made from metal old one was plastic... added significant weight.

           - 225 miles on timing belt change no notable leaks or weird sounds.  (short storm chase & drive back from minnewaukan)

To DO:
Boost gauge
Stage 1 flash
Deal with rust under front bumper.


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#16 2012-10-01 17:34:58

Moto
Member
From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

Noticed some oil usage on road trip to WI and back.  2/3 quart over 1000 miles. (oil was added at 400 miles so it never got very low) It was very hot outside driving speed was close to 80 for much of the trip.  Research revealed that it is not particularly uncommon given is was using the Mobil 1 with specified motor oil weight.  I may switch to something a little heavier for the rest of the summer, and I will now closely monitor the oil level.  (will be doing some follow up to make sure there isn’t a bunch of oil in the intercooler.)


PCV valve replacement and check for oil in IC (Aug 3 ~106K miles)
Did not seem to be much oil in the intercooler.  Just a small amount in a low area on the engine side.  Nothing wet on the turbo side.  PCV valve replacement was fairly easy other than some clamps that were difficult to get apart.  No real noticeable oil consumption in the last. 800+ miles

Stage 1 flash Aug 2012 ~106k
Didn’t really want to flash to stage 1, but when installing the access port it forces you to pick a map other than your stock one.  I can probably change it back now.

Trying to troubleshoot boost issue.  I must have a massive leak. on the intake side of the turbo.  I ordered all new lines for the intercooler and intake.   It looks like the intake side could be a major pain in the ass.

The battle of the heat shield...
https://sphotos-b.xx.fbcdn.net/hphotos-snc6/243451_10100325202189295_1037636931_o.jpg
Should have been 7 of these
https://sphotos-a.xx.fbcdn.net/hphotos-snc7/287980_10100325202259155_1301794620_o.jpg
https://sphotos-a.xx.fbcdn.net/hphotos-ash3/561679_10100325201805065_1904687418_n.jpg

Fixed boost issue Sept 2- 4 ~106k & tire ordered
Replaced all intake and intercooler hoses.  Also replaced gasket for intercooler. All changes showed no improvement. (most of the the lines were really rotten so it wasn't a total waste)
NEVER REPLACE YOUR TURBO INTAKE HOSE UNLESS IT IS ALREADY LEAKING!  That little project was by far the biggest pain in the ass out of anything I have done on the car.  I ended up cutting the old intake out.  Long story short.  The job sucks.

Removed heat shield on turbo... It took a whole day to get the heat shield off.  All of the bolts were totally rusted.

Problem ended up being the arm on the wastegate actuator had fallen off because the e clip (6mm) holding it on had rusted through and it fell out. ($0.22 fix)  facepalm

Cleaned and fixed the heat shield as best I could.  (Back up to 5 out of 7 bolts holding it on)

https://sphotos-a.xx.fbcdn.net/hphotos-snc7/287952_10100325202074525_573769665_o.jpg


Oil Changed to Castrol Syntec ~106k
driving

1000+ miles since oil change still some usage, but not too bad.

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/267175_10100345538609945_1394191396_o.jpg



To DO:
Deal with rust under front bumper

Last edited by Moto (2012-10-04 22:52:36)


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#17 2012-11-25 00:56:43

Moto
Member
From: Grand Forks & EGF ND/MN
Registered: 2012-03-09
User Number: 7120
Posts: 238

Re: New guy from North Dakota (currently the the edge of MN)

Tightened screw on passenger side fuel injector. 
http://www.youtube.com/watch?v=wx2dFSgl7LY
https://saab92x.com/viewtopic.php?id=17792

Had noticed raw fuel smell on cold starts.
I did not notice any residue, but I could only access one screw.   
Will update if problem is resolved.

While I was messing around I figured I would take a look at the cabin filter.  I had no idea if the previous owner had changed it or not.   Nope. unamused

Last edited by Moto (2012-12-03 09:54:07)


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