Project "Rely-on-ability" : 6 bolt rebuild

[blcknspo0ln]

Yep, I have a healthy 37 miles of VROOOOM brrrrrrrrrrrrrrrrrrrrrrrr going on the car. After talking to Bruce (oldman) he pushed me over the fence to do a moto-man break in. First 5 miles were all of boosting, engine braking, revving to 5k, and over all being an ass in my neighborhood . I will be doing a final retorqueing of the headstuds to 90 ft/lb once I stop being lazy, but the main update is that the trans is going to have to come back out.

The oil galley plug is leaking, again. Tell tale sign I've figured out is wetness near the transfer case and ultimately a steady drip of FRESH oil that accumulates on the slave cylinder. I'm pretty much 100% on it being that galley plug because I started and wondered about that same leak all of 2007. Well, back to the drawing board. I'll be pulling the trans next time out and going back into the galley plug with *Permatex Form-a-gasket-sealant 1B (fast dry hard set)* recommended to me by Chris @ JNZTuning. I'll also be coating the circumferance of the plug (leaving the allen exposed) with some JBweld for good measure. Hopefully that will be the last time I'll be dealing with that insidious plug.

Other than that, dialing in LTFT lo/mid was spot on with DSMLink, g/rev was good, and she held 25 psi on a boost leak test just fine. The only thing I must note, whether it be a combination of the 280 cams or the elimination of the FIAV/ISC on the TB, I cannot get the car to idle for the life of me without holding the throttle open for the first 2 minutes of cold idling. If I start the car and let off the throttle, the car immediately shuts off. How silly.'

Oh, and lastly, the oil started looking normal again, I guess all of the lubricant I used really did affect the color. I changed the oil/filter at 15 min of idling, zero miles; then 1/2 mile (oil/filter) ; then 5 miles (oil). Currently using pennzoil regular oil 10w-40 with an oem filter.

[90laserRSfwd]

I have a FIAV block off plate and my car idles just fine. Not sure why your having that problem. Good luck with it and let us know how you make out with that oil galley plug.

[tqmx1]

You are not going to weld the plug! I am truly hurt

[outkastracing]

wow very good post i think that this is the best ive read on here yet! i look forward to reading more of yours!!!! and using it when i do my build

[talonTSIDriver]

Wow, nice job Tom! You seem to have the "ability" to make it "reli-ability"

NICE WORK!!!

[packinkimber45]

This is really informative. How come the pictures aren't shown anymore? Thanks.

[blcknspo0ln]

I got pwned by photobucket. It's ok, I upgraded

[blcknspo0ln]

Originally Posted by 90laserRSfwd

I have a FIAV block off plate and my car idles just fine. Not sure why your having that problem. Good luck with it and let us know how you make out with that oil galley plug.

I think it's more due to the ISC not being there. It's ok, I hardly ever drive the car so staying on the throttle for 2 min for idle doesn't really bother me.

Originally Posted by tqmx1

You are not going to weld the plug! I am truly hurt

TRUST me, if I had the resources, I would weld that sumbitch up and never look back. For now, this permatex/jb weld combo is gonna have to do.

Originally Posted by talonTSIDriver

Wow, nice job Tom! You seem to have the "ability" to make it "reli-ability"

NICE WORK!!!

Thanks andy, I'm a little depressed that I focused so much on having a correct build, but that's the nature of the beast I guess, something always goes wrong.

[squeak10686]

are there any relative and helpful threads on gapping your own rings?

[blcknspo0ln]

Wow, it's been a while since I've thought about this thread. Here's a brief recap of the past month:

I couldn't take the crappy cold starts anymore, so I ordered the FIAV eliminating TB plate and put my lower half of the TB and ISC back on. Ever since then, beautiful startup, idle, and cold idle.

Oil pan was dropped THREE more times. Twice with brand new oil pan gaskets and a bit of great stuff and they both leaked. After a bit of research, I took off the oil pan, banged the mating surface straight, cleaned it off about a hundred times, blasted it with air, then put on a BIG (read: HUGE, like half the bottle) amount of great stuff all over the oil pan. I let it set for 15 minutes and pushed it onto the block. The pan STUCK to the block without any bolts on! I put all of the bolts on (not even finger tight) and let the great stuff cure for another hour. After that I went back and tightened it to 10 ft/lb in star pattern of tightening. I let that cure for 72 hours before putting oil in and firing her up. So far, 50 miles (total of 123 miles now) and no leaks!! fyi, did you know that our engines did not come with an oil pan gasket from the factory? I sure as hell didn't.

After that, both the battery and the alternator crapped out on me. Autozone graciously replaced BOTH under warranty, so no worries there.

I also got a new turboback exhaust 2.5" before the flex and 3" all the way back out.



*edit* New DSMLink log, not too shabby considering it's state of tune

[alex99gst]

Awesome. Keep it up Tom, I love this thread.

[Atuca]

I just spent the last good hour or more reading this thread. Amazing work, and I am amazed you were able to keep the camera so close to you during all these steps in building the motor.

The engine looks amazing, and I can't wait to see waht you do this season. Grats to you sir!

[123bobby123]

Originally Posted by blcknspo0ln

I also got a new turboback exhaust 2.5" before the flex and 3" all the way back out.

Hi,

Hopefully it works better then the piece I cut for you, haha. Looks great man.

Also, why do you have such a high timing pull due to knock?

Bill

[blcknspo0ln]

Hey bill,
It's been a while, how've you been? anyway, I was having serious issues with my charging system and it turns out BOTH battery and alternator were bad (200 miles old from autozone/duralast); but they replaced them for me. Oh and stop worrying about that downpipe. I told you, it fit/sealed perfectly fine and you cut it as much as I would have (which barely was enough room to fit the bolts on btw, so it's not like you overdid it). !! I just felt I've finally reached the end of the 2.5" and decided to go larger.

One of the wires from the knock sensor harness frayed itself, so that's the reason why knock/timing is so screwed up. Mitsugraveyard is sending my new plug as we speak, so I should be able to have a more consistent log in a bit.

[123bobby123]

Originally Posted by blcknspo0ln

Hey bill,
It's been a while, how've you been? anyway, I was having serious issues with my charging system and it turns out BOTH battery and alternator were bad (200 miles old from autozone/duralast); but they replaced them for me. Oh and stop worrying about that downpipe. I told you, it fit/sealed perfectly fine and you cut it as much as I would have (which barely was enough room to fit the bolts on btw, so it's not like you overdid it). !! I just felt I've finally reached the end of the 2.5" and decided to go larger.

One of the wires from the knock sensor harness frayed itself, so that's the reason why knock/timing is so screwed up. Mitsugraveyard is sending my new plug as we speak, so I should be able to have a more consistent log in a bit.

Hi,

I've been good, just real busy trying to find a job. Glad you got the electircal issues all figured out, they always suck. I thought the knock problem was some sort of failure/wiring issue becasue it is a constant 3.2 degrees timing pull through out most of the log, .

Bill

[eclipse08]

Just an FYI for the throttle body seals. I have been searching for better fitting tb shaft seals as my aftermarket ones didn't fit as well as I would like them to and came across WORKSEvo's website. They have a high pressure tb shaft seal kit for their Evo that also fits our 4g63 engines, they look like a lot better quality than the others I've seen, and the rep. I spoke to there said they have had no problems with them in the few 1g/2g cars that have them installed.
Here's the link:
WORKS
When I spoke to them they informed me the price may vary slightly due to the fact that different gaskets would be needed to fit the tb to the intake manifold.

[4Motion4g63]

Just spent 1 hour reading this thread and its got me Excited about my Up coming build....
I will Post a thread called " PROJECT OVERKILL"...... My goals are simular but I really just want a good reliable driver that hangs with the big dogs, I wont be taking mine to the track,
a low 14 or high 13 would be fine for me... I was thinking of going forged rods/pistons but everyone talks about the 1g/2g hybrid setup as just as solid? any Opinions on that?

Again nice build log and nice car its my exact dream DSM!!! always thought the Talon had the nicest lines and body kit.....Esp the 2g you have is the ULTIMATE!

oil leaks are a givin these cars mark there territory

[HIGHWAY]

great thread man

[TuRBoTaLooN]

Tom....make sure that motor's nice and broken in for Sunday!