XT turbo overhaul

A place to document members' special build projects.

Appropriate items would include things like:
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- window tinting
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Moderators: Hocrest, Myxalplyx, Huck369, Moodybluesr, grossgary, john in KY, SUBBYRU89, austinXT6

XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 3:15 pm

The overhaul. Of this engine start it when I did a compression test on this turbocharged 1986 xt.
By the way some one have recently put a head gasket, also engine taps. You know valve clatter,noise.
The test show zero psi of compression on cilinder number 3. I tear down the engine and find out ,that valves was NOT,
Sticking ,or broke, but the VLH's were frost. 4 of them. Including the ones on cilinder 3,
So anyway the engine is back on the car and running like a sawing machine, quiet and powerfully.
The upgrades include an engine oil cooler and a Saab Top mounted intercooler,
I don't want to start this tread if the engine overhaul went wrong, or never completed.
So I am going to star posting pics, from the beginning ,stay tune so you see my intercooler setup. 8)
Attachments
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 3:23 pm

Engine is out on the machine shop
Attachments
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 3:29 pm

Here is the intake Cleaning time.
Attachments
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 3:42 pm

I clean the injectors using 20psi from my compressor and a rigged a 12 volt supply than using fuel injector cleaner,
You know got the idea from you tube videos.
Attachments
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 3:46 pm

This are the old bearings, the crankshaft measure good so it stay standard ,also the rod bearings ,standard .
Attachments
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 3:51 pm

Note the top left piston is number 3 it was clean with no carbon build ,because ,wasn't firing.
Attachments
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 4:02 pm

Here is another picture of one of the pistons,it doesn't. Look too bad for an engine that was overheated, I think,
And have a 108000miles of abuse.
Attachments
image.jpg
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 4:15 pm

Here is the block as a got it from the machine shop,already. Assembled , they are professionals, and been doing race engine, overhauls, for 30 plus years, grifft's in Sandusky Ohio, they also install the front and rear seals. Of course.
cilinder sleve, was bored over .020 or 0.50 mm to fit the new pistons.
Attachments
image.jpg
image.jpg
image.jpg
image.jpg
Last edited by Sub6xt on Sun Dec 01, 2013 5:15 pm, edited 2 times in total.
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Sun Dec 01, 2013 5:09 pm

The heads are a generation 3 I think. Resurface , new seals and wherever else the did in the machine shop.
Attachments
image.jpg
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Mon Dec 02, 2013 8:00 am

I using felpro permatorque head gaskets,torqued to 53 ft lbs. using 3 steps, 22, 44, and then 53 ft,lbs 6 more than the fSM recommendations .
Following the advice of grossgary He is the man to listen when it come to subaru he has thousands Of posts. Also using his advice of hard wire the water temp sensor.
I am very particular when it come to head gaskets, I chase every tread hole on the block and ,cleaned with brake cleaner then blow compressed air,also wire brush the bolts tread,and apply oil to the treads, before torque them.
Attachments
image.jpg
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Mon Dec 02, 2013 8:35 am

I was waiting on the cam metal reinforced o rings, so next is the air intake ,using OEM ,gaskets of course, fuel injector,with new o rings,also replace every coolant ,fuel,and vacuum hose,note that is important to use fuel injector clamps on fuel injector hoses.also replace the air intake throttle gasket,included in the felpro set.
Again very important, to chase the tread with a tap, and I use new bolts for the air intake.manifold , I repeat, OEM gaskets.
And yes I use the cork oil pan gasket,but I have a technique to use with this type of gasket, this is what I do and they never leak on me: apply gasket maker black silicon on both sides of the cork gasket and let it dry ten minutes,then install on the block put the oil pan and the bolts and finger tight them,only go away and come back in 24 hours then tight them.do no over tight them,
Then the cam carriers for this I did use the subaru OEM liquid sealer, and the OEM metal reinforce o ring.
And torque to specifications,
The new valve lash adjuster are nice and soft, I put them in oil for a couple of days,and pump them with my hand,
$11.85 each at the part train
Then the valve cover gasket.,
Attachments
image.jpg
image.jpg
image.jpg
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Tue Dec 03, 2013 8:34 am

I should mention that when I install the oil pump, I packed with Vaseline to prime it, I got a timing belt kit from eBay,and
Put all the covers back on, some people prefer no to use them, but I disagree .they have acces holes if you want to readjust the belts,or inspect them.next the turbo,I use the felpro gaskets,but have to order the brass gasket for the turbo oil and
Coolant hoses .also the coolant rubber hose with insulation , the exhaust pipes, and a new clutch kit,
I got two new clips for the clutch bearing, from the dealer. And It is ready to go back in the car.
Attachments
image.jpg
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby grossgary on Tue Dec 03, 2013 9:35 am

tearing it up, wow!
Gary
89 XT6, rear LSD
02 OBW VDC H6
06 Tribeca
grossgary
Moderator
 
Posts: 11604
Joined: Wed Jun 18, 2003 9:34 pm
Location: midatlantic

Re: XT turbo overhaul

Postby Sub6xt on Mon Dec 09, 2013 7:47 am

Here is a pic of my oil cooler setup. And oil filter relocation ,I got from jeggs, it increase the oil capacity by 1.2 liters.
Everything included in the kit. I am going to make some aluminum brackets, but I got it setup ,in front of the fan.
Attachments
image.jpg
image.jpg
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

Re: XT turbo overhaul

Postby Sub6xt on Mon Dec 09, 2013 7:59 am

This is my intercooler setup,I am using a 1990 saab 900 TMIC , just have relocate a few hoses for the intake and move the solenoid for the 4x4 I think it is,
Using the original subaru aluminum intake ,I cut it and tig weld a pipe from the Saab intercooler,
And if make some aluminum brackets to hold it in place, is nice and solid.
Now I just have to modify the scoop to draw some cold air in to it,
Also going to make a shield for the distributor, so no water can get to it in case of a rainy day.
Attachments
image.jpg
image.jpg
image.jpg
1986 subaru xt turbo 5 speed. 4x4 (Digidash)
1988 Subaru xt-6 AWD 5 speed (Digidash)
2012 Nissan Titan prox4
2000 BMW 1100 RT motorcycle (boxer engine)
1998 Infiniti QX4
1980 porsche 928 euro 4.5 v8
Sub6xt
 
Posts: 56
Joined: Sat Sep 22, 2012 10:26 pm
Location: Sandusky Ohio

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