11 replies to this topic

[LukeFranky]

Back in November 2014 I bought this 2002 (MY03) Subaru Liberty B4 from Sydney. Had 165,000 KM on the clock. Was advertised for $8500, knocked him down to $6250.
 
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Previous modifications (that I know of):

• AVO pod filter
• GFB crank pulley
• Aftermarket secondary CAT (might be hi-flow)
• EcuTek tune
• White line front and rear sway bars
• Brandt disabled or removed
• Aftermarket alarm system

This car had a number of issues. First thing I noticed was an engine light when the car was started cold. Took it to the Subaru specialist in town as I didn't have a code scanner myself. They gave it a good once over for free (and promptly never saw me again). O2 heater element was kaput and there was a whine in third gear I hadn't noticed until they mentioned it.
 
Ordered the O2 sensor through one of my father's supplier only to be sent the rear one instead of the front. Got quoted a crazy price for the front A/F sensor so I went online... Plugged it in and all was good. Little did I know I had just created the biggest headache for myself later.
 
Initially I thought I got a good buy but with limited knowledge about twin turbos I didn't pick up that it had a low boosting primary too. I soon discovered I really had a problem when I occasionally tripped a turbo related code up steep hills. This code put the car in limp mode. The car would be struggling in the primary rev range but suddenly burst to life when the secondary engaged, only to be thrown forward in my seat due to the limp mode boost cut.
 
The McIntosh sound system had seen better days. Discovered it was 8Ohms so I ripped it all out and reran new wiring and installed speakers, head unit and a sub.
 
Saved up my pennies and found some similar turbos online. The VF21 and VF13. Bought and installed them. These bought the car to life. I was very happy with it despite a too lean error code. However, about a month later when visiting my family and about 10kms from their place the primary turbo blew up. Ended up limping through the main street of Bellingen with a huge cloud of black smoke behind me. The day before I had noticed erratic boosting and had found the wastegate hose split! Got 6km from my destination and car was really struggling, got out and checked the oil level. Bone dry. Poured a crap load of oil into it and managed to get there. It used almost all the oil I put in it over the 6km.
 
Pulled the car apart. Here's what I found:
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I hoped to find most of the shrapnel in the intercooler. Alarming found nothing. It had been blown through the engine. Knowing full well the engine could be stuffed, I rebuilt my original primary turbo using a kit I got online anyway. Discovered the primary had be seized due to oil leaking into the exhaust side and being baked on. Took to it with a wire buff. Threw the new bearings from the kit in and put it together. I didn't have the tools to balance it and knew it may not last, but 20,000kms or so later it is still working.
 
After this the car ran great apart from using a lot of fuel and throwing a too lean code. Replaced a number of parts in vain. That's when I joined SubyClub. Flogged the life out of that thread for a long time. Added a silicone intake pipe, phenolic spacers and new vacuum lines. Fixed air leaks, smoke tested it and ran diagnostics. Replaced the BBoD, MAF, CTS, intake manifold and much more. It was a hell of a journey and spent more money than I'd like to admit only to find out it was the knock off O2 sensors I had bought. Thanks again to all who helped.
 
During this troubleshooting sega I needed a new clutch. Ended up replacing the box to sort out the previously mentioned whine. It had got louder over time and sourcing the bearings would be expensive and difficult. Bought a HD clutch. In total cost me $1500. A bit disappointing that the new box has a few troublesome syncros, but still better condition than the old box.
 
I buggered up my rear passenger door when I scraped past a tap at my old place. It was in the most inconvenient spot. A friend ran it over the very next day. We plugged the hole so there would be no more victims. I also happened to reverse into an old Navara and stuff up my rear bumper. Got a new door and bumper from Kong. Door is on but I'm going to sand and spray the bumper. Also got keyed...
 
Had several flats over a short period of time. Ended up over-using the temp wheel and blowing it up too. Bought a whole set of BBS rims in good nick with new tires for $450. Ditched the temp and have a real wheel in the back plus 3 other spares at home. The last set of front tires got rotten inner edge wear so I got an alignment.
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I've done a few other things like sway bar bushes, battery, coil packs, plugs and replaced a fog light.
 
Anyway, this car has been a huge learning experience. A fair bit more complicated than the Magnas I had before. Up to 199,000KM now and the engine has survived being starved of oil, fed metal shavings from a blown turbo, messed up A/F rations and of course the odd flogging.
 
I still have a few things to fix...
 
Engine/clutch shudder:
Doubt it is the clutch. The fly was machined and spigot replaced, etc. Suspect it is engine mounts.
 
Cam shaft sensor:
Rough start up and idle, especially with the lights on. Suspect a bad earth or alternator problem.
 
Lastly, I'd like to build a box around the pod filter to help shield it from drawing in hot engine air.
 
I'll update this thread if I have forgotten anything or have new stuff to add.

[cowie165]

Wow. That is a lot of history and experience in just 12 months! Awesome pics too. I love the shot of the disintegrating turbo. Scary stuff.

 

Did you deliberately put VF21 and VF13 on your 208? I thought it was VF32 and VF33 for ADM B4?

[LukeFranky]

Did you deliberately put VF21 and VF13 on your 208? I thought it was VF32 and VF33 for ADM B4?

- Not deliberately, I would have gone for VF32 and VF33 if I could find some but because these were the only turbos that I could find at the time.

 

Trying to resolve the camshaft issue at the moment:

http://www.subyclub....ternator-issue/

[LukeFranky]

So I've done a bit of work on her since I last posted to this thread.

 

I solved the cam shaft CEL with a new alternator, but still have a miss at idle still exists and the car doesn't enjoy cold starts.

 

The rear bumper has been painted and fitted. Once I got it on I realised it needs more clear coat, but still looks decent. Photos to come.

 

Replaced the timing belt, cam shaft seals, water pump, etc. Cracking those cam shaft bolts off was a mission!

 

I installed a catch can because the intake was coated in oil. I'll do a write up with photos soon.

 

The work never stops with this car. Thankfully I enjoy it. Not happy that my new clutch started slipping though:

http://www.subyclub....lutch-slipping/

[LukeFranky]

Catch can write up: http://www.subyclub....aru-liberty-b4/

 

Diagnosed the rough starts to a fuel pressure issue. Priming the pump a few times (key on and off) before starting the car makes a difference. Got a spare fuel pump so I'll start by swapping it out sometime.

 

I don't park like a tool but have been keyed twice and now had a trolley scraped past my mirror. If you don't hear from me I'm probably in jail because I caught someone in the act.

 

Travelled in the beast over easter. She's pretty smooth these days. Overtaking is a pleasure. Have to constantly watch my speed or I'll be 20kms over the limit if I'm not paying attention.

[LukeFranky]

Time to add some details.

 

I've done a bit of work now and the car is 99% there now.

 

Bought and installed:

 

- A mild steel turbo back exhaust from a wrecker. I took a punt and bought it without hearing it on a car first, but it is cheap and sounds great! Got that deep boxer rumble but not so loud my neighbours complain.

 

- Pair of hybrid/ported turbos. Combined with the exhaust there was an immediate improvement even without a tune.

 

- Exhaust wrap for the dumps to reduce heat soak. Been warned it could cause rust, but I'm doubtful. Surely it still gets too hot and burns off any moisture.

 

- DIY'd an intercooler sprayer from bits I found at Bunnings and Autobarn.

 

- DIY cold air intake. Made from metal sheets from Bunnings cut to size with a Dremel, bent to shape and bolted together. Should keep some heat out of the intake and make the POD filter sort of legal.

 

- Front and rear dashcam with parking mode and GPS.

 

- Double DIN touch screen Sony headunit with Bluetooth. It is reverse camera compatible so I ran a wire from my dashcam.

 

- Second catch can for the heads.

 

 

Finally... I got a tune! It was only a road tune but made a significant improvement on performance and fuel economy. Supposedly it is 200kw ATW but I don't have a piece of paper to prove it.

 

The car is pulling slightly to the left and killing the inner edge of the tires again despite being aligned twice recently. Bought some new bushes but need to find a way to press them in and out.

 

If anyone wants photos or specifics about anything in particular let me know.

[El_Freddo]

Hey mate, awesome story! I've been reading most of your problem threads as they pop up. I thinking 90% of people would have burnt it and walked away by now!

And what's up with all the keying?? I didn't think people were still keying cars

Press for the bushes: I've used a G clamp and a selection of big sockets. Most of the time this has done the job for me.

Keep up the good work!

Cheers

Bennie

[LukeFranky]

Hey mate, awesome story! I've been reading most of your problem threads as they pop up. I thinking 90% of people would have burnt it and walked away by now!

And what's up with all the keying?? I didn't think people were still keying cars

Press for the bushes: I've used a G clamp and a selection of big sockets. Most of the time this has done the job for me.

Keep up the good work!

Cheers

Bennie

Thanks,

 

I work as a programmer so my job involves solving problems. With the car I can't help myself and like to figure out a solution...otherwise it bugs me.

 

I'll give the G-clamp trick a go. Sounds feasible.

 

As for being keyed, I dunno. Maybe I upset someone. I hasn't happened for a while now.

[duncanm]

front LCA bushes -- a bit too late, but you can buy OEM-spec Febest bushes with their S-shaped alloy mounts pretty cheap.

[LukeFranky]

Hey mate, awesome story! I've been reading most of your problem threads as they pop up. I thinking 90% of people would have burnt it and walked away by now!

And what's up with all the keying?? I didn't think people were still keying cars

Press for the bushes: I've used a G clamp and a selection of big sockets. Most of the time this has done the job for me.

Keep up the good work!

Cheers

Bennie

- My bushes are in there a bit too tight... Broke my G clamp!

[LukeFranky]

So an update!

 

Done lots:

• Installed cruise control (DIY guide on here somewhere).
• Moved the intercooler sprayer to the rear (better weight distribution and can carry more water). If anyone is interested I can do up a DIY guide.
• Diff bushes.
• Rear control arm/track control bushes.
• Rear shock bushes.
• Strut top mounts.
• Sparco gear knob.
• Sparco pedal covers.
• Front semi-slicks on some spare rims (Federal 595 RS-RR).

 

Re control arm/track control bushes

I replaced these caveman style:

1. Drilled out the rubber enough to remove the centre sleeve. 
2. Used a hack saw to cut through the bushing's outer metal shell.
3. Tapped out with a chisel.
4. Used a bench grinder to smooth the surface of the new bush.
5. Used hammer on the right sized spanner to smash the bushing in.
6. Cursed it then hammered some more.
7. Repeated steps 5 and 6 until properly seated.

Re diff bushes

I didn't remove the sub frame. Used a couple of bolts with big washers to pull the bush in. Even then it wasn't easy. Stretched one bolt.

 

Re rear shock bushes

One of mine was totally stuffed and the other one isn't far behind. No one makes these lower bushes so I went to Autobarn and got behind the counter to look through their bushes. Found a pair way too long but close to the right diameter. Shaved a bit of the outside shell then used a hack saw to make it the right length. Only done one side so far. The inner metal sleeve insert needed some adapting but my drill bit went blunt. Instead bought some metal pipe the right size from bunnings instead. All in all, a hack job but it works. Happy to do up a guide if anyone needs it.

 

 

TODO:

• Second gear (more on this below).
• DIY blast plates.
• Front camber bolts.
• Steering rack tie-rod ends.
• Steering rack bushes.
• Rear semi-slicks.

Future stuff:

• Slotted rotors.
• Fresh brake fluid.
• Better brake pads.

 

The bad news

I've been tracking the car. Been great for six months of abuse but I finally came unstuck... blew second gear. Been driving by skipping between first and third. I think replacing the diff bushes caused it. Mine were flogged but the flex might have been kinder to the gearbox. Stiffer bushes might have meant more shock on the transmission...well that's the theory.

 

Going to pull the box and and replace the broken parts with bits from my old box which was replaced because of noisy transfer bearings. While I'm at it I'm going to DIY some blast plates. Seen them online and reckon I can make them myself. Will it save me blowing another gearbox? Maybe, maybe not, but worth a shot as I can't afford to go six speed.