cripes...
 

*sigh* while exploring my engine bay this evening, i believe i may have found the root of at least some of my problems. there's a nice big crack in the manifold interface/injector plug/expensive hunk of metal part. it's part number five in this diagram -----> intake manifold diagram the section that has the crack is the part where the '5' is pointing to. it encompasses the whole front half of it...right underneath the place where the front flange bolt screws into. this isn't something the dealer should have messed around with when putting in my new engine, right? b/c the whole rough idle thing started after they put the engine in...and i believe the crack got larger sometime tonight b/c i have never noticed it before. basically, if i don't have my foot on the gas, the whole engine shakes and dramatically bounces the rpms (before it wasn't so bad and i could reduce the severity by turning on my a/c). anyways, sorry this is so long...there's really no way to repair something like this, is there? i believe it's covered under my warranty thing...but they're just a pain in the rear to deal with...oh well. anyone ever had anything like this happen to them???

Re: cripes...
 

Srmifer,

There are shops that can weld aluminum. Check them out in your area. This may be a solution. If you do this make sure that you pick an experienced shop. Don't go for the cheapest. Good Luck.

Re: Re: cripes...
 

aluminum...lol...i can weld that. i actually have all the stuff right at home to do it...i'm preeeety good at it too. this is probably something i should just have someone else do though. ok, obviously, i'll probably have to take the part off of my car and take it in to somewhere. plus, it's not very fun to drive right now. here's my question...how do i go about getting it off? i mean, there's the manifold attached to the top...the fuel rail on the side...if anyone could help me out with some instructions for removing this, i'd really appreciate it :)
~andrew

Remove collector cover.
Disconnect throttle and cruise control cables.
Disconnect engine harness connectors.
Remove female harness connectors from bracket
Disconnect auxillary air control valve electrical connector.
Disconnect two (2) coolant hoses from throttle chamber.
Disconnect auxillary air control valve hose from throttle body.
Disconnect PCV valve hose from valve.
Remove R.H. PCV valve from valve cover.
Disconnect EGR control hoses from intake manifold.
Remove EGR pipe cover and EGR pipe.
Disconnect power steering switch electrical connector.
Disconnect power brake booster hose from intake manifold.
Disconnect fuel hoses from fittings at fuel rail.
Remove drive belt cover and drive belts.
Disconnect alternator "B"/"+" connector from alternator.
Remove alternator harness cover fastener.
Remove alternator.
Remove A/C belt idler pulley. Remove A/C bracket fasteners and move barcket and compressor foward to facilitate removal of intake manifold fasteners.
Remove intake manifold fasteners and remove manifold

(with all credit to beav for these destructions)

see post http://www.subaru-svx.net/forum/show...&threadid=3641

edit:
I am a mostly grown man but if I looked under the hood and saw a crack in the intake manifold or block I am 99.9% sure I would break down and cry.

Good luck and I hope you get back up and running soon.

I would have to agree with immortal suby on how I might react to the same situation. I don't think that I would handle it very well at all. :(

Good luck with your project. :)

see, the thing that makes me pissed is before i had to get the engine replaced, the thing ran fine. so i have the subie ppl put a new engine in...i get it back, and it's all weird like. so i dunno...maybe just sitting there for a month and a half cracked it b/c some little evil spirit decided to be a pain in the butt :p but the subaru people were the only ones actually messing around with the whole engine area. but seeing i've waited this long now (about a month and a half)...and now that it's worse...it's pointless in me even mentioning this to them. go figure, eh? :rolleyes:

so was the crack there before they......
 

installed the new engine? did these guys not inspect it for you? jesus? i would be pissed off!!!

Re: so was the crack there before they......
 

see, i can't say for sure b/c i was not able to visually inspect it. i can only make a educated guess at it. when i got the car back it did this weird thing at idle...it would shake and kinda do a bouncy rpm thing. i thought this could be injectors, tps, and a bunch of other things after checking all those...and having them check out fine...it was still odd. then a few nights ago it got worse...would do it no matter what when idling. saw the crack...i never saw anything like it before...so i dunno. maybe stupid thinking to think this is the cause of it, but it seems like it should be. so they either didn't inspect it close enough...or they did it while installing the engine. either way...someone should have picked up on. :rolleyes:

you have got to go and have them fix it.
 

how could it be your fault? didnt they give you at least give you a 30 day warranty on the car? when they dropped my engine in i at least got a 90 day warranty.

Re: you have got to go and have them fix it.
 

they gave me a 2 year/24000 mile warranty on the engine. :) i'll call them later today and inquire about my little problem. heh...should i mention my radiator was cracked when i got i back? :p lol...i think we'll take one thing at a time...

hell yes i would mention it.
 

if you have the damn thing warrantied and they did a poor job it is your duty to have them fix it. not to mention you should not be responsible for repairing a car that was delivered to you damaged.

that crack was the problem. i got frustrated last night while trying to pull the part off, so i just put it all back together and thought about what i could do. first thing i tried (which was rather stupid), but i moved everything meltable out of the way and tried to see if i could braze it while still attached to the car. it spreads all of the heat throughout the manifold...anything touching it that's aluminum. i think i'd have to sit here for one hour heating it. scrap that idea...then i got out the jb weld for a temp fix...let it dry overnight...took the car out today. and guess what?! no more shaking, no more bouncing rpms, and it didn't sound like a damn diesel anymore! the loudest parts in that engine bay are now just the belts. so after trying everything else to fix it, this is the problem...now that's it's almost two months after i got my car back, i have to convince the subaru people that they screwed up and i just thought i'd tell them now. :D lol...in hindsight, i think this is the reason they wanted to replace my 02 sensors b/c it was shaking on them...you think they'd try to figure out why it really was having problems when replacing the sensors didn't fix it :confused: hey, sorry these posts of mine are so long...i just kinda ramble on. :rolleyes: