382 replies to this topic

[bobbyjimmy]

Just the top/upper part.

[JDWhiteWRX]

Guy on NASIOC suggested this:

 

"Remove the breather line (extreme right on your pic) and drill the pump housing in an area where you have space and insert the additional breather line...that new one will work as the return line instead of the broken one..
all you will need to do is blank off the existing return line and change the hose connector if yours has the "clip-on" version.."

 

Can anyone follow what he is saying exactly? I need to understand how the pump works and which line does what before I attempt anything like that.

[JDWhiteWRX]

Things are looking up!

I have managed to repair the fuel pump assembly for free and save myself some coin. I got some 6mm (1/4") copper pipe and had the guys at work turn it down to 5mm external diameter. I then grabbed a drill which was 0.06mm smaller than 5mm and drilled out the internal surfaces of the plastic nipple and where it attaches to the fuel pump assembly.



The copper pipe was then cut down so it would fit about 10mm into each piece of plastic.



It was lightly sanded down so I could almost push it into the plastic pieces, tolerances were super tight. The some 2 part epoxy on one half of the pipe and I forced it into the cracked off part of the fuel pump assembly, the glue acted as lube allowing me to get it right in.



I had marked where the fracture in the plastic lined up perfect on both pieces so I could line it up perfect when bonding it together. Once the other half (the nipple) was pushed on I ran a little extra epoxy around the crack.



Even without the epoxy the tolerances are tight enough that I doubt this would leak but the epoxy will help with the overall strength.

Next step was to fit the new fuel pump to the assembly, just pop these tabs off (one on each side) and push down. Then to remove the fuel sock there is a little circlip under the rubber base.



Here is the comparison of the stock Outback pump with the DeatschWerks 65C to suit a MY08-13 WRX



Here is a shot with the new pump in the housing.



I have taken the under bonnet fuel filter from the Foz and installed it in my Outback so no need to keep the in tank fuel filter and no need to ever remove this fuel pump assembly again after this. I just removed the filter being careful with the o-ring, if that is damaged there will be no fuel pressure. I greased the o-ring and metal cap a little before re-installation to make sure no damage was done.



I also grabbed a couple of irrigation fittings at bunnings today so my head breathers could be routed under the new intercooler, the old TMIC has a metal pipe on the front for this.

My mate Rob came over last night to do a few little wiring jobs for me, did I mention I don't like wiring?

Anyway we needed to hook up a relay for the water to air intercooler water pump and splice it into the fuse box under the bonnet with a fuse etc. We mounted the relay right in front of the fuse box.



Next job was to wire in a 3rd wire to the alternator, the turbo motors have 3 wires going to them so we de-pinned it from the Foz harness and joined it up to the plug the guys at AM Auto left there for me.



Finally the fuel pump controller was spliced into the harness and mounted up under the dash, the guys left enough wire coiled up so I could run it under the carpet and back to the fuel pump connection where it was spliced in under the back seats.



The plan is to start it up tomorrow afternoon

[Morgan]

Freaking awesome!

[Liberty]

I'm gone for two weeks and there has been so much progress. This is an amazing build man!

[JDWhiteWRX]

Its alive!



I have an airbag light on the dash and check engine light comes on after about 2 minutes of idling. Going to download learning view and see what the code is.

[Morgan]

Congrats dude!

[Beckers]

Nice job, so quick to convert.

I bet ya felt good when it started ??

[sbv]

Awesome news. Well done mate!

[Liberty]

Sounds great and really good to see it started perfectly.

[Hypnotic]

WOOOO!

[JDWhiteWRX]

Yes very happy it started   there are still a number of things to do though, hopefully I can get them all sorted this weekend because my exhaust shop guy is back from holidays on Monday and it would be great to drive it there Monday morning.

[bobbyjimmy]

Sooooo, want to get rid of that brake valve and bracket now?

[JDWhiteWRX]

Good news, the CEL is just a minor fault to do with the idle control solenoid or IACV. Its nothing major and I will be driving to work on Monday in the car via the exhaust shop. It could aslo be due to the neutral switch.
 
Hopefully I can track down the airbag fault today, I'm hoping its just something I didn't plug in, I put the drivers seat back in and plugged it in but the light stayed on.
 

 
 
 
 

Sooooo, want to get rid of that brake valve and bracket now?

 
Not sure mate, I am going to order some brake pads front and rear to see if I can improve the performance as they were a bit lacking even with the n/a motor. Can't decide between QFM HPX or A1RM, might talk to the guys at GSL Rallysport before ordering.
 
So if I can't get good performance with new pads I may swap the Foz parts over so I don't want to sell anything off just yet.

[JDWhiteWRX]

Airbag is fixed, it was just a plug in the drivers side kick panel that had been joined but not fully seated in the plug ( a little green button needs to click). I washed it and then took it for a drive around the block, it needs better brake pads

[Barbbachello]

Skids video isn't loading?

[JDWhiteWRX]

Still have half a tank of 95 or possibly 91 in it, need to use that up first before I can open it up

[CRUISN]

Congrats. A job very well done and something I have quite enjoyed following the progress on. 

[allpaw4]

Well done. Very interesting to watch as it progressed. Hope you enjoy it. If you want to hasten the fuel use, I beleive there is a bolt in the drivers side fuel tank that acts as a bung. Unbolt that and you can drain most of the tank. Well, there was one on my B4, so I dont see why there wouldn't be one on the outback. Make sure you have a few large containers though, I got about 25L out of mine.

[JDWhiteWRX]

Well I drove the car to work today via the exhaust shop with no muffler, sounded mean The exhaust lengthening was finished by lunch time and after work I went and got the A/C re-gassed. I also filled the tank with premium ULP and checked all the tyre pressures.

Here is a shot of the exhaust, its very stealth.



When I got home I got to work fixing the CEL issue which was a IACV which controls the idle. A little net research and it turns out you can take it apart and give it a clean which in most cases fixes it.

First step was to unplug the two connectors and unscrew the IACV.



Have a look how filthy it was inside.



So I basically blasted and soaked it with upper engine cleaner, wiped it out with rags and cotton tips and reinstalled it.



After that I reset the ECU and took the car for a drive through the Natio. The idle issues (idle hunting) and CEL were gone and the car was running sweet, plenty of punch out of the corners and loads of fun to drive

So here is the before/after shot of the engine



Still needs a wheel alignment and need to put the sump guard back on but otherwise there is nothing more to do but enjoy.