Finally finishing up the Outback - up soon - back to the diesel

Well, it's been a longer road than I would have originally thought, but I'm just about done with the Outback now. Although the car ran well when I bought it, I needed to catch it up on a lot of maintenance and tune-up items, most of which I detailed in this blog.

Recently, I finally installed the new steering rack boot. As the passenger side boot was still intact, and it's still cold here, I opted to only replace the torn boot.

I also finally replaced the missing exhaust manifold stud. I was going to replace 2, but one hole had apparently been drilled and tapped to a larger size. So, that bolt had to stay in place, for at least the time being.

Next, I replaced the cooling system hoses, which looked original to the car, and then washed the car and cleaned the engine compartment.

Then, yesterday, I got the fog lights working. The factory ones didn't work. I put a new bulb in the driver's side, and it worked for a few minutes, but the passenger side light was corroded on the inside past the point of no repair. Given how hard these lights are to find, I opted to install a pair of aftermarket lights which also use H3 bulbs. I'm pleased with the new lights. They work well and don't look too out of place.

So the next time you drop in for a read... I'll try and have some Mercedes stuff for you. I'm glad to be getting back to that project, and that the Outback is now solid.

Still working on the Outback, but nearing end

I'm certainly missing the Mercedes, but we keep getting hit by snow. This has had the unwanted effect of slowing down the work I've been doing on the Outback.

I did have a bit of luck. I found out that I didn't need to replace my starter. I had some difficulty trying to get the old one out, but in the process, I cleaned the electrical contacts. Thankfully, that seems to be all it needed. I've been driving the car for over a week with no weirdness at all from the starter.

I also (finally) changed the rear differential fluid. Unfortunately, I damaged the magnetic drain plug in the process and had to revisit the job a week later to install a new drain plug. Luckily, I was able to install the new plug without losing more than a few drops of gear oil.

I also managed to polish the headlights and clean the windshield (in and out) to improve visibility while driving.

BEFORE

NOT MUCH DIFFERENCE, BUT... AFTER

I'm probably forgetting a few items, but I still need to replace the exhaust studs in the cylinder heads (and the manifold gaskets) and the cooling system hoses. Once that's done, the remainder is all cosmetic, and I'll be able to devote my free time to working on the Mercedes again.

Sorting out the Outback

So, I've been delayed in getting back to working on the Mercedes. I've been putting the Outback together, but mostly have been delayed by weather. It's snowed pretty much every weekend for the past month. But, I try to do at least a little something each week.

So far, I've done the following:

• transmission fluid flush
• changed front differential fluid
• changed spark plugs
• new air filter
• new PCV valve
• fixed interior lighting
• installed stereo from my old car
• fixed/replaced broken/missing interior trim
• replaced missing alternator tensioning assembly
• replaced accessory drive belts
• replaced valve cover gaskets
• replaced vehicle speed sensor 2
• replaced battery

I still have a few more items to take care of, but the weekend weather has slowed me down significantly. But, I'm daily driving the car and am getting closer to having the car caught up on its maintenance items. Once that's done, I'm getting back to work on the diesel. 

Here's a few pictures of this weekend's work (the speed sensor replacement):

I'll leave you with a few videos I've done of some repairs to the Outback:

The new daily driver arrives

I've been away from the Mercedes project for a few weeks now. The daily driver Subaru took a turn for the worse and lit a fire under me to get a replacement car sooner rather than later.

I hadn't seen any promising Toyotas or Hondas in a while. I came to my senses and pretty much scratched Volkswagens off the list after I went to see the Jetta that wouldn't start. Pretty much every Volvo I looked at needed a lot of expensive work. I even got to the point where I was considering rear wheel drive Mercedes, just to have something reliable.

Well, as I said, the Legacy kept getting worse. The check engine light was constantly on, and blinking with alarming regularity. Plus, the engine's idling was getting even choppier, and I believe it was using oil at an increasing rate.

Two weeks ago, I saw an ad for yet another potential replacement car - a 1995 Subaru Legacy L... Outback. This was a 2.2L car with an automatic transmission. Based on the ad and a phone conversation with the seller, it sounded like the car was in decent shape. So, that Saturday morning, I packed my wife's car with an assortment of tools and we drove an hour to see the Outback.

It was a first-year Outback and even the same Mica Ruby color as both our other Legacies. It wasn't perfect by any means. It was wearing beat-up alloy wheels and had a green hood from an old fender bender, and had bumps and bruises all over. Plus, it was sitting on an ugly set of beat-up alloy wheels. But, my philosophy is that an old Subaru should look used, much like an old truck. The interior had been cleaned - something I hadn't seen in a used car in quite some time.

The car started right up and sounded pretty good. The test drive went pretty well, so with the seller's permission, I pulled out the spark plugs (old, worn-out, and nearly seized into the cylinder heads) and ran a compression test. Compression was healthy across all four cylinders, so we made a deal and I drove home in my new daily driver.

I spent most of the rest of the weekend swapping parts over from the old car, starting with the correct Mica Ruby hood and my wheels. Then, I put the old car up for sale on Craigslist. Unfortunately, with winter weather and street parking bans, I had to get rid of the old car quickly. In its condition, the only interest I had was from junkyards, and for a lot less than I wanted. But, the car was getting needier by the day. At the last moment, a co-worker who was painfully aware of the car's mechanical condition showed interest and I let him have it for scrap value. He intends to repair or replace the engine. So, the old car will live.

I've been driving the "new" car pretty much every day and handling maintenance and repair items as time allows. New spark plugs are now installed, which is a good thing, as the old ones were worn to twice the recommended gap. I also flushed the transmission, which made a big improvement in the way the car shifted. I'm still trying to properly dial in the fluid level, but it's close now.

Overall, I'm happy with the new car. Once it's caught up on needed repairs, I'm going to move back to the Mercedes project.

When I got it home - green hood and all

The alloy wheels

Rear shot - this car has a factory roof rack

Firsr year Outback - badged with a sticker only

Side shot with my old wheels on it

Complete with correct red hood

The search is on - new daily driver

My last blog post was around Christmas. To recap, the misfire problem on my 1995 Subaru Legacy (which I thought I'd fixed last Spring with a new cylinder head...) returned in late December. Rather than throw parts at the problem again, I opted to cut straight to the heart of the matter and run another compression test.  My P0302 code was caused by low compression in cylinder 2. Cylinders 1, 3, and 4 tested OK.

More accurately, the low compression was causing (over time) carbon buildup in cylinder 2 that in turn interfered with combustion. I bought some Seafoam spray and fogged the engine through the throttle body. I ended up doing this several times. In the end, I probably ran a can and a half through the engine. Just after Christmas, the wife and I took my car to visit my family (200 mile trip). The Legacy made it there without a hiccup, but the CEL came back on while we were there. Thankfully, it didn't blink - it just went on and stayed lit. I had my scanner with me, and once again - P0302.

We made the return trip a few days later. The car drove OK, but I had a few seconds of blinking. Once we got home, I put a can of Techron in with the next gas fill-up, and once again, cleared the codes. I've been driving the car for over two weeks now, and although for some reason the car isn't yet showing readiness, there are no pending trouble codes, and that's in around 1,000 miles of driving. So, in the end, the Seafoam and Techron cleared out the carbon buildup.

The car is perfectly driveable, and I've always known to keep the oil level in check. But, now that I know for a fact the engine is less than 100%, I think it's time for me to move on. The car still has some life in it - a lot of life, probably. But, I want something a bit more hassle-free for the long distance driving I do.

So, I decided to start looking for a new (to me) car. My first choice, obviously, was another EJ22 Subaru Legacy, or perhaps another EJ18 Subaru Impreza. Of course, it didn't take me long to realize that both are an endangered species at this point. There are very few left in the northeast that aren't overpriced high mileage rustbucket. So, I decided to expand the scope of my search for the first time in years to include other makes and models.

My first instinct was to stick with the Japanese cars. So, I started searching for 1990s-era Hondas (Civic and Accord) and Toyotas (Corolla and Camry). Among them, my top choice was the Camry. I quickly learned that most of the for sale by owner ads for the Japanese cars are run by shady small-time car flippers and dealers posing as private sellers. I've been in that situation before - that's how I ended up with my current Legacy.

I test drove a Camry, but it turned out to be a dealer posing as a private seller, so I walked on principle, even though the car seemed OK at first glance (I had reason to suspect hidden problems). Note to that particular dealer - if you want to describe an interior as "mint," take the duct tape off the dashboard first.

I even (against my better judgement), went to check out a 2000 VW Jetta. But, at $1200, it wouldn't even start for a test drive.

I've been keeping an eye out for Toyotas, but a co-worker actually clued me into another car to keep on my radar - 1990s Volvo 850 and V70 station wagons. I've always liked Volvos, but we haven't had a decent one in the family yet. But, I did some reasonably intense research and liked what I saw. The Volvo shot to the top of my list.

I've test driven 2 850s already. I'm still considering the first one, but the second one had too many problems. I have an appointment to test drive a 1998 V70 also, which is essentially a lightly-updated 850.

Even pushing 200,000 miles, these cars feel about 10X more solid than the Subaru Legacy, have a good reputation for reliability (overall, with some well documented problems and fixes), and most importantly, are well within my price range. For the cost of a rusty Legacy, I can get a much nicer Volvo. So, that's what sold me, and that's what I'm looking for.

Of course, if the right Legacy, Impreza, or Camry comes along at the right price, I'll probably jump on it.

Learning when to call it quits...

Well, it looks like this may be the beginning of the end. If you've been following along, you know that I replaced the cylinder head in my 1995 Subaru Legacy daily driver earlier this year, which supposedly cured a misfire issue I;d been having.

As of this past week, the misfire is back, unfortunately. The car threw the same P0302 code again. I did a compression test and verified that I have low compression in cylinder 2. This is the same test I did back in April. I had meant to re-test the car after replacing the cylinder head, but never got around to it. Earlier this year, cylinder 2 clocked in at around 70 PSI. This time, it's showing around 100 psi, which is still bad compared to the other three cylinders, which are showing 165, 165, and 160.

I'm not 100% sure why the misfire took so long to return, but it may be because I cleaned the carbon buildup off the cylinder 2 piston when I replaced the cylinder head. To buy myself some more time, I ran a can of Seafoam through the car this past weekend and replaced the spark plugs. As it is, I think I'll get through the winter (most likely with the check engine light coming on at times). But, come springtime, I'm hoping to be driving the Mercedes project, and hopefully can start looking for a "new" daily driver.

I was hoping for more miles out of this car (I've put around 45,000 very well maintained miles on the car as of now). But, the car has never run quite right for me. I'm guessing that cylinder 2 has been problematic for as long as I've owned the car, most likely due to mistreatment by a previous owner.

Because of the car's overall poor cosmetic condition, including rust, a rear suspension crossmember that's suspect, an aging transmission, an already-patched gas tank, a leaky cooling system, and numerous other issues, it's probably not worth it for me to try and replace the engine, and rebuilding it is out of the question. So, I'm most likely going to end up replacing the car. With what? Time will tell.

Hello, old friend

There's nothing to report on the Mercedes at the moment. I've been unable to touch it for a few weeks, but hope to get a bit done today (Columbus Day). But, I made a quick stop at the junk yard on Saturday and ran into a familiar face...

It was my wife's old 1993 Subrau Impreza. You may be asking how I know this was the same exact car. After all, they made about a million of these in the same color. Well, I only sold the car to the junkyard (this junkyard, in fact) around a month ago, so it makes sense that it would still be there. I know every bump, scratch, and rust spot on the car, as well as identifying marks like stickers. Trust me, this was the self-same car I'd been working on for the past three years.

In the past few weeks, the car has taken a turn for the worse. The month-old alternator that was in the car when I sold it is long-gone, likely now under the hood of another Subaru. Other various engine parts were gone, but the block and intake were still there. Someone really should buy the engine. High miles or not, it's a really good runner with a fresh timing belt.

For whatever reason, the rear and rear right windows were smashed. My guess is some punk just wanted to break windows. The rear wheels were missing (the fronts were still there). Part of the dashboard and center console were gone. The rear seat had been disassembled for some reason. I'm not sure why.

I didn't find the part I originally wanted (a rear cargo cover shade for one of our Legacy wagons), but I actually did end up buying the rearview mirror out of the old Impreza to replace the more worn one in my wife's "new" Legacy. So, after a month in the junkyard, a part of this car followed me home again. The mirror is a direct fit, but the older mirror in this Impreza was, in my opinion, a better design, and less susceptible to wearing out. The later Legacy mirrors tend to get loose and flop around with age.

I imagine the Impreza will sit in the yard a while longer, but who knows for exactly how long. It may be there for another month or two, and then it'll likely be crushed and melted down. But, in the mean time, its parts are going to save other old Subarus.

Junking the Impreza - a lesson in wreck-o-nomics

So, a couple of weeks ago, I finally finished work on my wife's "new" car - the 1995 Subaru Legacy. This finally freed me up to start working on the 1983 Mercedes 240D. Well... almost. My wife's old car, the 1993 Subaru Impreza, was still taking up valuable real estate in the driveway.

In addition to taking up space, it was still on my insurance policy, costing me money every month. My original plan was to sell the Impreza as soon as the new Legacy was on the road. Fate had other plans. In recent months, the car had started to deteriorate sharply.

Back in April, I had to replace the driver's side front CV axle. In June, my wife drove the car on a 2,000 mile road trip. To make sure she got there OK, I replaced the timing belt and idlers, did an ignition tune-up, replaced the transmission fluid, and replaced the fuel filter. In early August, I had to replace the alternator. (Interestingly enough, when I bought the car in 2009, the seller told me it had a bad alternator - well, that bad alternator performed flawlessly for just over three years... until now) Bottom line, the Impreza was starting to nickel-and-dime me to death.

The last straw came the same day that I got the "new" Legacy on the road. One of the Impreza's brake calipers all but seized up. The car would run and drive, but the pad was worn out and was metal-on-metal with the rotor. My wife had told me she'd been hearing an intermittent scraping sound for the past few weeks. I hadn't bothered to check it out, as I was concentrating on fixing the Legacy. Well, the caliper finally froze. Also, the transmission was starting to bang into second gear intermittently.

So, I put the car up for sale on Craigslist. I wrote a long, almost encyclopedic ad, detailing everything wrong with the car. I could have fixed the brakes, but I wasn't interested in putting more time and money into the car, knowing that would likely not

I set an asking price of $800, knowing I'd come down with the price, but not wanting to give the car away. Aside from the usual scammers, the only interest I had was from a college student who wanted to pay less than scrap value for the car.

Knowing I wasn't going to be able to sell it on the open market, I started calling local junkyards. I got a variety of price quotes, but one, located about a mile away from the house, offered me $400 if I could drive the car in. I grabbed the title, pulled our stuff out of the car, and drove it up there. I hate to junk a running, driving car, but it had 326,000 miles on it and needed more work than it was likely worth, including, possibly, a transmission replacement.

We had the car for three years. We bought it with 240,000 miles on it, and drove it 86,000 miles. I originally paid $175 for the car (I did have to replace some parts over the years, but surprisingly, not too much). I sold it for $400. In my case, it just made the most sense to retire it and let its parts keep other cars alive.

I hope someone can make good use of that month-old alternator. Anyhow, here's some photos and video I took the last day I had the car.

The projects continue... and multiply

As of my last post, I had just gotten my daily driver Legacy back on the road after a cylinder head replacement. All went well there, and the car has been back in daily service, seeing around 90 miles per day since then.

So, now that I had transportation again, I decided to get back to working on the Vanagon again. I spent the next few weekends working on it, starting with installing the flywheel on the new engine. Eventually, I got the engine bolted into place and installed.

Finally, last weekend, I got the engine to start, albeit briefly. It doesn't seem to be getting fuel, so I suspect that either the fuel pump went bad from sitting dry for six months (I drained the gas tank when I put the van into storage), or there's a blockage somewhere. I need to do further diagnosis.

But, here's a video of it starting on starting fluid (sounds pretty good for an engine that sat for at least a year and a half):

I would have done more diagnostics this weekend, but I was busy with something else... As you may remember from previous posts, I've been looking for a new car for my wife for quite some time now. I finally found it, and it's something familiar:

No, you're not looking at my 1995 Legacy. This is my wife's... 1995 Legacy. Actually, the only difference between the cars is that hers has an automatic transmission, fewer miles on it (115,000), and has a working air conditioner. I didn't buy the same exact car on purpose. It was just the first decent 2.2L Legacy I've seen in my price range in a while. I've been buying tune-up and repair parts all week and will be working on this car shortly. Once it's done, I'll be selling the 320,000 mile green Impreza.

Here's some video of the Legacy. Enjoy:

Delayed by a major breakdown...

Apologies to anyone who's been reading in the past six weeks looking for updates on my regular projects. I really haven't touched the Vanagon or the 240D since early April. I've been busy with the Legacy.

Right around the time of my last blog post, the Legacy started running poorly and throwing a P0302 trouble code. I threw a few parts at the car, hoping it would be a simple fix (spark plugs, wires, a new coil, and finally, a fuel injector). None of this changed how the car ran, and no matter how many times I reset it, the code kept coming back.

So, after throwing money down the drain on non-returnable parts I didn't need, I did what I should have done in the first place - I ran a compression test:

The results were conclusive, showing low compression in cylinder 2 as the cause of the misfire. From the specifics of the test, it looked like a burned exhaust valve or a worn valve guide was likely the cause of the problem. So, after some brief soul-searching, I decided to go ahead and repair the car. The clearest path to that goal was replacing the cylinder head. Learning how to do that was enough without having to learn how to rebuild it myself.

I ordered a rebuilt cylinder head from F&S Auto Parts in Roxbury, CT, who I found highly recommended on several Subaru message boards. They rebuild cylinder heads to order, so I had to wait a little over a week for the part. In that time, I did something I hate to do - I commuted to work by train. Frankly, it's crowded, overpriced, uncomfortable, and the schedule is horrible. But, at least I was able to get to work.

For a while, I felt like an urban redneck. I had three cars at home, none of which I could drive. Finally, my cylinder head arrived, but not without difficulty. Let me paint a picture for you...

It was a sunny Saturday morning, around 11 AM. I was home, and, anticipating the arrival of the cylinder head, I went to look out the front door to see if the local mail carrier was on our street yet. I saw no sign of the mail truck, but found the day's mail in the mailbox, along with an attempted delivery notice indicating for my cylinder head. I needed the part, and in a panic, tried calling the post office (I got no answer). Not knowing what else to do, I started searching the neighborhood in my wife's car, looking for the mail carrier. I found a succession of trucks and carriers, none of whom were my mail carrier, but who were all helpful. Finally, one of them directed me to a street around a half mile away from my house, where I found another truck. I waited like a madman (as politely as I could) for the carrier to return. When she did, I was happy to find that she had the cylinder head, and was happy to let me have it just so long as I signed the delivery notice.

My prize in hand, I sped back to the house and started tearing into the Legacy. By the end of the day, I had the intake manifold off. By the end of the weekend, the new cylinder head was installed, but the engine wasn't buttoned-up yet. By the middle of that week, I had the car back on the road, running better than it ever had since I bought it.

So, on top of that, another weekend that I was horribly sick, and this past weekend, when I replaced a CV axle on my wife's car:

...I haven't had any time for the Vanagon.

But, I've budgeted most of the upcoming long weekend to wrench on the van. I am still planning on having it back on the road for the summer.

The Mercedes is running and the Vanagon is in storage...

The title of this post says it all... but as usual, I'll say more.

As per my last blog post, the Vanagon made it home after Transporterfest, but only courtesy of a AAA tow. My long-term plan is to do a Subaru EJ22 engine swap. I've been around the original VW waterboxer engine since my parents bought their first Vanagon in 1985, and have owned my stock Vanagon since 2003. So, this isn't a snap decision. I've seen these engines fail more often than they work properly.

I didn't want the van to rot in the driveway while I saved and made preparations for the engine swap, so my goal has been to get it into the garage. In order to do that, I needed to move the Mercedes out.

The problem with that is that the Mercedes hadn't been so much as started in the better part of two years. I've been working on it bit-by bit - bodywork mostly up until this point. Thankfully, I'd been maintaining the battery. Still, I had to do a marathon of maintenance before the car would start:

After the Mercedes finally started, I took a chance and started the Vanagon. Amazingly, it wasn't completely dead. It was weak, noisy and smoky, but drove into the garage under its own power:

So, as it is, I'm currently trying to sell the Mercedes, for two reasons. First, I need to start raising money for my engine swap. More importantly, I just can't have two big projects sitting around. The Vanagon was my backup car. It's my project now. As such, I'll need to get something a little more roadable for a backup car.

Losses and gains - what's in it for me this time?

Egad! It's been nearly a month since I updated the old b-log. And what an unfortunately eventful month it's been.

I'm not going to beat around the bush. The Vanagon is dead. Well, "mostly dead" anyway, to steal a line from Billy Crystal. As per my last post, I was having suspected oil pressure problems. I plumbed in a gauge and drove it locally a bit. Everything seemed more or less OK. I even attempted to install a tachometer:

The results of the second oil pressure test with the tach installed were inconclusive, due to poor quality aftermarket gauges. So, I decided to drive a little more locally to test the van. I was planning a trip to New Jersey, which should have happened this past weekend, and wanted a few more local miles under my belt before I took a long trip in the van. So, a week and a half ago, I decided to take the Vanagon to Transporterfest, a VW bus show at the Larz Anderson Auto Museum in Brookline, MA.

The van handled the first part of the trip OK, but as it really heated up at highway speed, the oil pressure began to drop. By the time I got there, the light was going off intermittently. Not a good sign. So, I enjoyed the show, and when it was over, I decided to head home. It was a 40 mile trip there and back. Well... I didn't make it back. Actually, not true. I did make it back home, but with the help of AAA and a ride from my wife:

Long story short, the van will probably start, but a scant 300 miles or less since I completed all the work, and the engine is pretty much dead. As I don't have the money to fix it (yet), I de-registered it, de-insured it, and am preparing to get it into the garage for long-term storage.

Bottom line, I don't want to sell the van. I don't need to, and in its current mechanical condition, it probably wouldn't sell for much. So, I'm a bit sad. After almost eight and a half years, the van is no longer usable. But, this is where we get to the point of this particular blog post.

In the past, every time I've had major car problems, I've learned something or otherwise gained from the experience. Conscious of that trend, I'm trying to take as many positives out of this experience as possible.

Most of all, I'm going to use this to complete a long-time goal of mine and learn how to swap a Subaru engine into the van. Once I can save enough money for the conversion parts, I'll be dropping in a Subaru EJ22 engine, just like in my Legacy. I know the engine very well - even better than I know the Vanagon's engine at this point. Putting one in a Vanagon, though... that's going to be a learning experience.

But, it'll be a long while before I have the money for the project. So, in the meantime, I'm going back to working on the Mercedes 220D project. I dug it out this past weekend:

It hasn't even been started since April, 2010. I'm hoping to have it running again this weekend so I can get it out of the garage and clear up that space for the Vanagon. I'll be resuming work on the Mercedes outdoors. As much as I didn't want to work outdoors in the winter again, I'd prefer to do that rather than leave the VW outside. When it's done, I do plan to enjoy it a bit, but will eventually sell the Mercedes to help fund the Vanagon engine swap.

Vanagon done, other stuff, and what's next

Since my last blog post, I was actually able to finish work on the Vanagon. Overall, it shouldn't have taken this long to get it done, but life has a way of interfering with my free time. What, specifically, you ask?

First off, the Subaru's alternator failed on me:

and I fixed it:

and the bearing in the new one went bad two weeks later, necessitating another replacement:

Oh, and there was Hurricane (err... Tropical Storm, that is) Irene:

Plus there's the usual routine maintenance around the house and on the cars, as well as my day job to keep me busy.

So, this weekend, I finally got the van together and was able to take it out for a good 30 miles. I ran some fuel injector cleaner through it and it's purring like a kitten now:

I can't convey with pictures how much cleaner it is inside and out. Even before all the work, it photographed pretty well, even when dirty. You'll just need to take my word that this is actually a major improvement. The looks now approximate the way they were when I was regularly taking the Vanagon to shows years ago. Mechanically, it's pretty much there, too.

Here's a walkaround:

I'm happy. I hope to still make it to a show or two this year. Now that the van is done, I plan to take care of a few bodywork-related items on the Legacy and my wife's Impreza (rust spots). Once the Subarus are done and ready for the winter, I'm going to start back in on the Mercedes 220D.

It's been a couple of months since I touched it, and I'm eager to get back to working on it.