Subaru EG-33
Overhaul/Modification


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Valve train idlers and gears installed but not yet aligned for belt installation
The crankshaft and both camshaft gears must be aligned correctly for belt installation to ensure that the valve timing is correct.

 

 

"Right" cam pulley timing mark aligned

Crankshaft timing mark aligned

"Left" cam pulley timing mark aligned


 


Valve timing belt installed and timed correctly
The Subaru valve timing belt is marked so that once all three drive gears are aligned with the case index marks, the belt markings are then aligned with those same marks then the belt is tensioned.  This method ensures that the crankshaft/valve timing is correct and is easily accomplished.  It's possible to install the belt "backwards" though so it's not quite "foolproof"...

 

 


Valve cover installed

 

Now that the engine is essentially in a "long block" configuration, we can begin to install the accessories:

 


Mocking up the intake manifold and accessories
Normally, the intake manifold would be clocked 180 degrees from the shown orientation.  In our "rear engine" application, it's necessary for us to install the intake in the shown orientation.  As you can see here, there is insufficient clearance between the throttle body and alternator without additional spacers under the intake manifold.  The boards acting as spacers here are approximately 3/4" thick but provide about 1/4" more space than we need; we'll fabricate 1/2" spacers from aluminum for the final install.

 

 


Intake manifold spacers we fabricated from 1/2" aluminum plate

 

 


Spacer plates installed, intake manifold secured

 

 


Here you can see the the intake manifold/alternator proximity
Spacers fabricated and installed; we now have plenty of clearance between the two assemblies in addition to a clear path for plumbing the air filter(s).

 

 


Ignition "coil packs" installed
Continuing the assembly; coil packs installed, injectors coming soon and the ECU wiring harness to follow.

 


Custom fuel rails
We fabricated these custom fuel rails to replace the rails that came with the engine.  The supplied rails didn't have provisions for retaining the injector "O-ring" seals - they had smooth bore injector pockets that could allow the seals to "migrate" off the top of the injectors, causing a major fuel leak and fire hazard.

 


Properly machined injector pocket
We needed special tooling for milling the fuel rails correctly; it consisted of a large (3/4-16) tap for the "O-ring" seal AN fittings at each end and a custom tool for machining the injector pockets.  That custom tool made drilling the hole, step and "lead-in radius" an easy, one step, operation.  With the new fuel rails correctly machined, the injector seals will be retained from both the bottom and top, eliminating any possibility of them "escaping" and causing a fuel leak. 

 


New fuel rails installed (Passenger side shown)
Our new fuel rails fit perfectly and are leak-free under pressure.  We were also able to eliminate the "sketchy" features that bothered us with the previous rails; the new rails are safer, more secure and easier to service.

 

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