Legacy GT Wagon
2005 Subaru Legacy GT wagon
Subaru is a unique automotive brand; they build primarily AWD utilitarian cars that are powered by horizontally opposed engines. They are most known for building some of the most reliable engines, and some of the most problematic engines at the same time. The EJ22E being incredibly reliable and almost every turbo engine being prone to a multitude of issues. Some issues are due to shortcomings in the design, but most issues being a product of inadequate care.
The story of Jake's Legacy GT wagon began like many people's first turbocharged Subaru tales go; with major engine failure...
Jake knew purchasing this car was risky; it was a 180,000 mile EJ255 and despite having an impressive repair history and seemingly well-cared for life, it broke.
From the factory there are some shortcomings to these cars; such as cast pistons prone to fracture, a very sensitive oil system, turbo banjo fittings with filters, and even problematic areas in the factory ECU maps. Knowing the issues with the factory tune; Jake connected with a local tuner. While out street tuning, without even touching the boost, the engine developed rod knock.
The tear-down of Jake's factory EJ255 yielded an array of major issues that were all ticking time bombs; multiple bearings were wearing down and one was completely toasted, cylinder 1 was running lean, and one piston had a small cracked ringland. This engine was on it's way out.
A decision had to be made; whether to build this block with forged components or to order a factory assembled shortblock. This, in a lot of ways, is the hazing period of many new Subaru owners. After a lot of research and discussion with Flat Irons Tuning Jake decided it was worth being one of, or possibly the first, to swap in the EJ257 Type RA shortblock.
The Type RA is a 2019 STi variant that boasts 300hp figures along with updated internals to try and solve the shortcomings of earlier predecessors.
When a bearing fails in any engine it will send debris into any area that oil touches, which obviously places your turbo at risk. Inspection of the VF40 did not yield any real worries as to it's own failure but Jake opted to replace it with a upgraded VF52 turbo which has slightly better efficiency and output. This turbo came off of the later production EJ255 engines in the WRX.
We sourced a rebuilt VF52 from Hillcountry Forced Induction and had it ceramic coated the compressor housing was powdercoated in a wrinkle red. These are standard practice by Hillcountry along with full rebuild and balance.
One of our most popular videos is the detailed break-down of how bearing failure creates additional work when rebuilding or replacing engines. We show viewers how to clean components, which items to replace and the tear down and cleaning (as well as risks) to re-using the AVCS pullies.
Assembling the engine is pretty straight forward and any components that were able to be powdercoated and cleaned up were done so. The engine bay was cleaned thoroughly and once the engine was assembled we dropped it back in place.
If you are ever in this predicament, and if you are a turbo Subaru owner then you probably will someday, make sure to follow proper engine break-in procedures. Normally we break engines in with abuse (the ol' break it in like you're going to drive it method), but with Subarus it's been found that IAG's Break In Procedure is the most reliable procedure for ensuring your new motor's rings will be properly seated.
