An FA20D failure / diagnosis & repair story...

[NoHaveMSG]

Originally Posted by ZDan

13 feet, that *is* a LONG block!

I’m always compensating.

[FR-S2GT86]

I'd say that's overcompensating.

[Opie]

Realized that I actually had the main bearings, it was the rod bearing that have not arrived, so I got the block halves cleaned out and cylinders honed, installed the main bearings, checked tolerances, all journals were in spec so went ahead and assembly lubed the crankshaft and reassembled the partial short block. Yes, I still need to install the rear main seal...

Then got to work installing the left-side cams in the carrier and reassembling them. Temporarily bolted them the cylinder head to keep the rockers in place, so it is ready to go. Started on the right-side head, removed cams, carriers and rocker parts. Started cleaning them up. Dropped those right-side cams and carriers off at the machine shop this morning to be polished like the left ones. I’ll get them back tomorrow or Sat

Still waiting on rod bearings to install the pistons and new rings. Going to clean all the carbon off the pistons once I get the cams & carriers back from the machine shop. May start cleaning the RTV off the timing cover & oil pans today…

Found out the engine gasket set did not include the cam carrier screen filters, so headed to the dealer after lunch to pick those up and a set of spark plugs.

[blsfrs]

Did you disassemble and clean the cam phasers? You might need them clean in case you meet some Klingons.

[Opie]

Originally Posted by blsfrs

Did you disassemble and clean the cam phasers? You might need them clean in case you meet some Klingons.

I had the machine shop do that for me as they had to remove them to polish the cams. And at $50 per pair of cams for all of that, it was worth it to me!

[Opie]

Installed the rear main seal yesterday, also went to the dealer and picked up the cam carrier filter screens and a set of plugs. Machine shop got the cams & carriers done in a few hours, picked them up yesterday afternoon so I went ahead and assembled them, and temporarily installed on the cylinder head to keep the rockers in place. Right side is now also ready to be reinstalled.

Also got all the RTV off the upper oil pan and started on the front timing cover. Going to dissassemble the oil pump and passages to clean them out as well.

So far I've used a 1.5 cans of Subaru's Silicone gasket remover, probably 15 regular razor blades and 30+ plastic razor blades to get the RTV off....there is A LOT, like really a lot...everywhere. This stuff works great once you've gotten the thick parts off. Getting to the point where there are just small things I can do until the rod bearings show up....

New parts purchased so far for a little over $1,100:
Engine Gasket Set (OEM)
Crankshaft (OEM)
Connecting Rod (OEM)
Strainer/Oil Pickup (OEM)
PCV Connector (OEM)
4 Spark Plugs (OEM)
4 Screen filters (OEM)
Set of Rings (OEM)
Block halve O-ring (OEM)
Main Beaings (King Racing)
Rod Bearings (King Racing)

While the Engine gasket set is the best, most cost efficient way to buy most of the gaskets you would need, it is missing a few things to be aware of...here are the things I know I will need but are not included in the kit, some have already been bought, some I'll buy as I get closer to installing them:
Cam Carrier Screen filters (4)
O-ring between block halves (1)
O-ring for strainer/oil pickup (1)
Lower oil pan seals (2)
I'm sure there will be a few more....
Injector seals (port & direct)

BTW, Dawn Powerwash Dish Spray works great to clean aluminum parts...

[Opie]

Holy crap these cleaned up nice, 2 done, 2 to go.

[blsfrs]

Have you thought about porting the oil passages in the timing cover?

[NoHaveMSG]

Don’t forget head bolts. I am waiting on them since I forgot to order them.

[Opie]

Originally Posted by blsfrs

Have you thought about porting the oil passages in the timing cover?

Not at all, really don't see this as a big need. And if done wrong could lead to pressure issues elsewhere.

Originally Posted by NoHaveMSG

Don’t forget head bolts. I am waiting on them since I forgot to order them.

Per the Subaru manual, the Cylinder Head bolts are reuseable. The connecting rod bolts however, are not...those have been ordered.


As I continue to wait on the rod bearings...I think I've now done all I can do until they arrive (expected on Wed Jan 31st). Today I finsished cleaning everything. Including the oil pump. Got all the old debris out of the engine. Then reinstalled all the sensors and front seal on the front timing cover. Installed the lower oil pan to the upper oil pan, Installed the thermostat houseing and thermostat with a new gasket. Realized that I need a new water pump gasket...so that will be picked up shortly. It should be a quick reassembly once the rod bearings arrive...

[Ultramaroon]

Why did we not see a single pic of the crankshaft? I am disappoint.

[NoHaveMSG]

Originally Posted by Opie

Per the Subaru manual, the Cylinder Head bolts are reuseable. The connecting rod bolts however, are not...those have been ordered.

Doh

Didn’t realize that. I’m doing new ones anyway since the engine I am putting together will be for boost.

[Opie]

Originally Posted by Ultramaroon

Why did we not see a single pic of the crankshaft? I am disappoint.

The damaged one? Here it is...

[Ultramaroon]

Why always #3? Grrr...