Zax Bugeye "Shaggin' wagon" Build thread

[zax]

Well, I finished my drivers' side injector install this evening. This wasn't the first time that I have worked on my car at night, but it was a little intimidating considering what people "say" about injector installation. I started at 9:40 PM, so it was already dark when I started the install.

Intercooler, battery, and washer fluid reservoir out (routine for me):


DS GBOD and cylinder head vent:



You have to unplug the DS TGV in order to get the GBOD out:


GBOD and cylinder head vent out!!


Stock Injectors are now visible:


Removing the bolts on the fuel rail:


Injectors are out!!


DW 750cc Injectors are in


I finished the install at approx. 10:45 P.M., so the installation wasn't as bad as I expected!

The GBOD and stock injectors:

[EJ257]

Solid progress

[Mikie13]

Nice Zach!

Newb question...what the hell is a GBOD?

[RayfieldsWRX]

Green
Bracket
of
Death

[zax]

Nice Zach!

Newb question...what the hell is a GBOD?

An unofficial term NOT coined by SOA or mechanics...

Green Bracket Of Death

[96accord]

Newb question...what the hell is a GBOD?

How long you been around Subies?

[zax]

How long you been around Subies?

Drunk or Sober?

[Mikie13]

Drunk or Sober?

hahaha seriously.

And I've never done anything with a GBOD...so why would I know what it is?

[Drews]

Well, I finished my drivers' side injector install this evening. This wasn't the first time that I have worked on my car at night, but it was a little intimidating considering what people "say" about injector installation. I started at 9:40 PM, so it was already dark when I started the install.

I forgot about that little guy. It's only like that on pre 06s I believe. I assume you just got a longer piece of hose to replace...

hahaha seriously.

And I've never done anything with a GBOD...so why would I know what it is?

Yeah guys...he's running a sweet stock STI...cut him some slack!

[zax]

OK! Injectors have been installed! The Passenger side GBOD removal was a little more involved. The injector install (from start to finish) took about 2.5 hours, though the majority of the installation involved re-installing the passenger GBOD since the bracket actually supports the coolant overflow tank and coolant lines.

Heat shield, intake, and TMIC brackets removed:


Passenger GBOD visible; must remove the bolts holding the coolant overflow:



Cylinder head vent will not come fully off, but it must be swiveled to remove the lower bolt on the GBOD:


This bolt (in the shadow) by the passenger TGV actuator is a PITA but is necessary to remove the GBOD. Would have been 10x easier if I had already pulled the turbo:


GBOD is out!



Stock injectors and fuel rail:


Injectors are out!


DW 750cc Injectors are in!


GBOD re-installed:


All 4 stock injectors:

[zax]

Part one of two installing the 18G into my wagon. There is a trick to un-mating the downpipe from the turbo... evidently it is possible to unbolt the rear exhaust hangers and move the exhaust backwards without dropping the downpipe. Unfortunately for me, it seems that my Kartboy exhaust hangers dont offer enough slack, so I'll have to drop the downpipe after all :-/

Anyway, here is a shot after I capped my coolant feed line (I used a 1/2" drain plug). You really do have to be quick with your hands else you'll lose a lot of coolant.



Here is a photo after I removed the stock oil feed line. I will be replacing the oil feed line with a SS feed line.


I broke so many vacuum lines for the BCS in my endeavors to remove the GBOD, work on the turbo, etc. Fortunately, I am replacing the crappy stock bleed-type EBCS with a Grimmspeed interrupt-type EBCS! Before/After:



Downpipe bolts being removed:


I was able to remove all of the Downpipe bolts from within the engine bay which is nice... I really wanted to keep from climbing under the car in 102 degree heat, but my exhaust hangers have other plans :-/

This bracket was such a MOTHER****ING PITA (for the third time)!!!


I ended up dropping the whole bracket from the chassis


The exhaust hangers removed:


BUT, I'll have to drop the whole exhaust tomorrow morning

BTW, I fitted my Fujita CAI for install. It was a pain considering I have no instructions. It turns out the heat wrap was too much to fit through the fender. I had to trim the wrap:


This is what it will look like installed:



More tomorrow morning!

[Drews]

Good work!

[zax]

This morning I dropped my downpipe. For the second time, those stupid exhaust bolt tensioners were a PITA. I broke one (again) and the other was so rusted I had to cut it off. But the downpipe did come off, and that's what matters:


Then it was routine to pull the turbo out:


I didn't rip the turbo inlet!!!!!!!


The turbo internals were in GREAT shape. Minimal shaft play, no binding, hardly any visible scoring. MHI makes a hell of a turbo.



Since I have an SS oil line, I removed the stock oil line:



And here is the SS line installed!


Two snails:



For those of you who may remember my review, I had a bit of an issue with the Grimmspeed uppipe that was shipped to me: the bolt pattern was slightly incorrect and this necessitated taking a dremel to the turbo flange. It seems that I will need to do the same with my 18G, so I'll be completing the installation tomorrow.

[michaelwfox]

Good job on not ripping that inlet!

[Calvinball]

Wonderful writeup Zach, it's lookin great so far!