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2001 Impreza L | WRX swapped | Rust repairs and weight reduction!
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Old 04-24-2016, 07:12 PM   #161
RavensFan77
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Default 2001 Impreza L | WRX swapped daily | Damage repairs and weight reduction!

^^^thanks!

-----

Finally figured out why the Legacy GT has been running so weird since I bought it a few months ago, and recently developed cylinder 4 misfires.

Cyl. 1 = 130 psi
Cyl. 2 = 130 psi
Cyl. 3 = 135 psi
Cyl. 4 = 10psi


Most likely a valve issue since there is no smoke at all. I'll have that headache figured out this week hopefully.

-------

-So back to important things....taking the Impreza apart.

--> Got the battery tray and washer fluid holder off last week. Underneath those panels was pretty crusty from the years. Another small panel that holds the horn and bumper beam also had to be removed to get the battery tray out.






--> Removed the passenger wheel tub/apron today. Pretty sure that's the last damaged panel I needed to remove. I'll be ordering the new panels very soon.

There was atleast 50 spot welds to drill for this whole panel, probably more.

I'm hoping to keep the remaining core support pieces. Won't know till I get the new panels and see how everything lines up....but I should be able to make it all work.









--> Haven't decided on a color for the bay yet. I'm gonna smooth lots of things out, re-paint it, and make the wiring look better.

Fender still bolts on, along with the hood strut mounting point. Still need to find a new hood, preferably aluminum or fiberglass.






Last edited by RavensFan77; 04-24-2016 at 07:28 PM..
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Old 04-25-2016, 04:49 AM   #162
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damn fine work so far.
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Old 04-26-2016, 09:11 AM   #163
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awesome thread! Love how you get detailed pictures and take us through the entire process. Subbed
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Old 05-03-2016, 04:17 AM   #164
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Originally Posted by George.of.the.Jungle View Post
damn fine work so far.

Thanks. This must have been the easy part, no tools were broken or thrown.

Fitting the new core support pieces and making sure all the exterior stuff still lines up will probably be more difficult/tedious. Just trying to take my time, since I've never done this kinda stuff before.

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Originally Posted by MajorLazer View Post
awesome thread! Love how you get detailed pictures and take us through the entire process. Subbed

Thanks!

I try to include pictures and details so I can go back and reference it later if needed. I can never seem to hold onto paperwork (or laptop hard drives), so keeping all the important info online helps out a ton.
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Old 05-03-2016, 04:38 AM   #165
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Default 2001 Impreza L | WRX swapped daily | Damage repairs and weight reduction!

It's been raining constantly, so I didn't get as much done this week as I wanted.

--> Started grinding down the TONS of little nubs that were left over from drilling the spot welds. Some spots I drilled too deep so they'll get filled in better, then grinded down again, before the new panels go in.

Only like 100 more to go.









--> Then I started on some wiring things. Once the rain stops, I'll start cleaning up wiring in the bay, but for now I just worked on the engine since its inside.

-Re-soldered the #3 cyl. injector, and cleaned it's wiring up a little.

The first time I soldered a new tail, I made one of the wires too short, and it was putting stress on the connection. Never had a problem, but it always made me nervous:



When I first got the ej205, the engine harness was damaged, and the replacement harness also had damage.....so I was forced to splice a few things.

This is much better for now....I'm going to source a new engine harness anyway, because I want to de-pin and remove a bunch of unused wires....like a/c, p/s, TGV's, ect.








Also, one thing to note, I had to remove the clutch disc and pressure plate to get the engine onto the stand. It was very close but the pressure plate interfered with mounting the bellhousing to the engine stand mount.

Didn't think that would be an issue, but oh well. Gave me a chance to check it all out.....seems like the 06+ WRX stuff is doing just fine.

So now it sits in a box:


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Old 05-10-2016, 03:18 AM   #166
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Default 2001 Impreza L | WRX swapped daily | Damage repairs and weight reduction!

Once again it rained pretty much every day last week besides Sunday, with more rain all this week. If I had a garage the car would be almost done by now. Oh well, just gotta work between the rain.

-> Anyway.....I finished grinding down the remaining spot weld nubs. Total, for everything I removed, I'd say there were 90-100 spot welds to drill....might seem like a lot, but it could be drilled in a day if you knew where everything was.









-> Almost everything in the bay is taped off or covered up, and sprayed with an initial coat of primer.....a very rough first coat.......still need to do more work before the full primer/color coats. Have to remove the wiper motor thing, my master cylinder brace, and some other stuff.

Now I can start making all the wiring and hoses look better. I'll probably pull most of the wiring and hoses out before I start spraying the actual color too.



-> Starting messing with de-pinning connectors and stuff with an old harness. Much easier than I thought. Seems like most connectors on this engine harness can be taken apart with just a small flat head, and/or needle-nose pliers.

Replaced a broken connector on the ej205's harness this way. The engine doesn't use this connector, but I figured it's better than just taping up the 3 terminals into the loom.....this is a connector that will eventually be removed though...






-> Ordered the new core support pieces as well. I was at a dealership yesterday getting parts for the Legacy, and the parts dude said there was only 2 wheel tub/aprons left in the country!!! So I had to order.

Was only about $300 for all the parts with a sweet online discount at the dealership. Not too bad considering what other OEM stuff goes for.

First picture is pointing to the wheel tub....only a couple left!




Last edited by RavensFan77; 05-10-2016 at 06:17 AM..
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Old 05-10-2016, 06:43 AM   #167
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in this pic, is the rail bent inwards? or is it just the angle of the pic that makes it look like it is?
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Old 05-10-2016, 09:38 AM   #168
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in this pic, is the rail bent inwards? or is it just the angle of the pic that makes it look like it is?
It probably is bent just slightly....but I think the picture makes it look worse. Bumper beam still bolts up easily, so it can't be too far off (I hope).

Or are you talking about the small kink right before the crossmember?
That kink was there before my accident, and before I even bought the car.

It's possible to replace the rail I think. The dealer sells those panels....but I'd like to try to make it all work without replacing the rail.
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Old 05-10-2016, 10:04 AM   #169
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right abouve where the crossmember bolts to the frame, looks like a ripple and a slight turn to the center..
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Old 05-10-2016, 10:43 AM   #170
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Just as an FYI, the service manual has all the measurements for the the car for panel replacement and to check what is bent.

These PDF's on this page will be very helpful ensuring that everything will line up:

Directory /Auto/Japan/Subaru/Impreza/1996-2001 Service Manual/BODY SECTION/Body and Exterior/Specifications/
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