Street Build bkrathwohl's Galant VR4 #1228/2000

[bkrathwohl]

I mounted my power steering pump today and played with routing the high pressure line. I decided to route it similar to the stock routing.

I need to finish up my 8an low pressure line tomorrow.

 

[bkrathwohl]

Sunday I was able to finish up all but one fitting on my oil cooler. The last fitting has been ordered, and a 8an to 6an reducer for the steering rack.

I started on my throttle body rebuild as well. I had a hard time getting three of the fasteners out of the lower half. Luckily drilling the heads mostly off loosened everything up.

I have a new TPS and some high pressure seals coming. I need to test my IAC to see if that needs replacing as well.

 

[92AWDHX40]

Nice I Put MILSPEC Seals On MINE I Like The POWERs steering Set up

 

[tunernewb92]

I went to ace hardware and got some new allen headed metric machine screws for my throttle body. Had the same issue.

 

[livedsm4g63]

From all the hard times we had installing tb seals....you should buy this tool.

http://www.dsmtuners.com/threads/throttle-body-rebuild-kit.479312/

 

[bkrathwohl]

I went to ace hardware and got some new allen headed metric machine screws for my throttle body. Had the same issue.

I thought there was a kit that someone made. I'll probably end up doing the same. I have the two sizes so i'll just take them to the hardware store and get similar SS fasteners!

From all the hard times we had installing tb seals....you should buy this tool.

http://www.dsmtuners.com/threads/throttle-body-rebuild-kit.479312/

I saw that!! I might have to pick one up.

 

[95eclipser]

On my old evo. When I rebuilt the throttle body, I messed up installing some milspec seals twice. It was very frustrating.. Wish I would have known about this tool sooner.

Third time was a charm but those seals arnt cheap .

 

[bkrathwohl]

Finally, after months of looking, I was able to find an engine splash shield! A little dirty, but nothing that can't be cleaned up. I'm still looking for fender liners that are in good shape, so if anybody finds some let me know!

I snagged a brand new OEM TPS from eBay for $25 bucks as well.

Next up is half of my stainless steel fastener orders.

And the result of having mounting hardware!

Oooooh It looks like a car!!!!!

There is a weird gap between my driver and passenger headlight. I'm not sure why, I need to dig further into it. It looks like the front garnish is bent down. I might take the headlight out and try to bend it up a tad.

The passenger and driver fender fitment is a little bit off as well. The passenger side really butts up against the A-Pillar while the driver side fits how I would expect.

 

[livedsm4g63]

in before full frame damage. jk. Looks great.

 

[bkrathwohl]

Since there are no good pictures online on how the bumper bar and supports go into the bumper cover, here they are. Forgive the messy garage.

Sadly I found that the bumper cover doesn't fit terribly well with this big of an intercooler core.

So the trimming begins... this took a hell of a lot longer than I wanted, but that's what TV is for I suppose.

It's still very snug, I may need to take a bit more off of the bottom.

I'm not sure if I want to remove any other spots off of the bumper cover. I want to keep it looking sleeper.

 

[livedsm4g63]

Wash me, the bumper says. Wash me.

 

[bkrathwohl]

I've really been putting off cleaning up the engine wire harness. Today I started digging into that. There are quite a few wires that have split. It's a mess.

I'll need to get some new connectors for some of these...and new wire.

 

[GST with PSI]

There is a weird gap between my driver and passenger headlight. I'm not sure why, I need to dig further into it. It looks like the front garnish is bent down. I might take the headlight out and try to bend it up a tad.

IIRC the Galant headlights have some little slots where the mounting bolts go that allow for minor adjustments. Otherwise, the garnish or core support may be tweaked.

The car looks awesome, man. Looking forward to you getting it back on the road.

 

[92AWDHX40]

More please it's gives us motivation to finish . Ohm racing has connectors.

 

[bkrathwohl]

IIRC the Galant headlights have some little slots where the mounting bolts go that allow for minor adjustments. Otherwise, the garnish or core support may be tweaked.

The car looks awesome, man. Looking forward to you getting it back on the road.

I've tried adjusting with no success. I'm guessing there was some sort of accident on my passenger side at some point. Even the A-pillar has some paint wore off from the fender. There's like zero gap there.

More please it's gives us motivation to finish . Ohm racing has connectors.

I actually have a big bag of connectors from dsm's and evos. I'm guessing I can find what I need in there!

 

[bkrathwohl]

I did a little more work on the harness. I peeled and re-wrapped most of it.

My knock sensor repair:

I chopped off the thermostat area wires and put some new extensions on. I am leaving these for now as I'm not sure what lengths I will need for my connectors (since they've been relocated to the back of the thermostat housing).

There were a couple wires on the ECU plugs that I had to repair as well, no snapshot of those though.

The oxygen sensor wiring is pretty brittle as well. I wasn't sure if I needed the wires if I simulate NB operation. It looks like they are not needed though!

 

[bkrathwohl]

I've got the harness all wrapped up. It's looking good!

I started with getting the the intake manifold routing sorted, as I know how that goes.

Then I worked on the firewall mounting. I didn't really pay attention when I pulled the wiring out of the car, so i'm kind of making it up as I go.

It looks like I need to do some more adjusting, the ISC plug doesn't even reach to the ISC.

This is how I ended. I'm just trying to figure out the stock route to see what I need to adjust or extend to lower the loom and keep my flex fuel sensor in place.

 

[bkrathwohl]

Some more goodies arrived yesterday.

Megan Racing 1g AWD downpipe, B2Designs Carbon Fiber Hood Struts, Master to Slave Clutch line.

 

[curt-s]

Just watch the flange angle on that Megan downpipe. Mine is slightly off and I had two bad O2 housings back to back with warped flanges from them.

 

[bkrathwohl]

Just watch the flange angle on that Megan downpipe. Mine is slightly off and I had two bad O2 housings back to back with warped flanges from them.

Thanks for your input, I will keep that in mind.

 

[bkrathwohl]

I ran my main power wire from the trunk. I used the empty rubber grommet by the ECU to get it into the engine bay.

I ran split loom tubing under the seats, that was put on after this picture was taken.

I picked up some 0GA and 4GA lugs from NAPA.

My injector seals finally arrived so I was able to get my fuel rail installed.

Some other goodies arrived as well.

I was able to find a set of fog lights WITH brackets too!

Happy doggo!

 

[92AWDHX40]

Nice vr4 build I forgot you can get wire at napa

 

[bkrathwohl]

My horns arrived! I went with the value range Hella Horns. I'm not huge on the typical Hella Horn sound, i'm hoping these sound normal.

Digging into the horn loom I find some pretty terrible wiring on both sides. Easy enough to fix!

I also toyed with lowering the engine harness.

I picked up an injector resistor and ignitor from a friend and purchased an 11" Mishimoto Race Line High Flow fan. I haven't really mounted my turbo, so i'm not sure what kind of room I have to work with. More to come on that.

 

[bkrathwohl]

On to a bigger project. Today I tackled most of the wiring in the engine bay. I've figured out the area that I want to mount my Evo X fusible link, now I just have to figure out how I am going to route things to it.

For the most part this fusible link is a direct replacement. These were the only things that were on my stock fusible link (note I do not have AC):

1) 30A Seatbelt Fuse (automatic seat belts)
2) 100A Alternator Fuse (two 8GA wires from the alternator to fusible link)
3) 100A to 60A 8GA power line to Fuse Box
4) Starter power line direct to battery
5) Fuse Box power line direct to battery

The 100A fuse will just move to the 120A fuse on the Evo X fusible link. I purchased an inline fuse holder for the 30A seatbelt fuse which will then run to one of the 80A fuses on the Evo X fusible link.

The fused fuse box power line will run to the second 80A fuse on the Evo X fusible link. The other power line will mount on the back on the battery post (no fuse).

I routed my alternator plug around to the alternator. It was too long so it had to be cut and soldered.

I replaced the two 8GA alternator lines, two 8GA fuse box power lines, starter power line, and starter ground with 4GA lines. I went ahead and wrapped the ends with red or green to signify power or ground as well. Visually it looks really nice, in my opinion.

After a lot of measuring, test fitting, measuring, test fitting, taping, looming, taping...I ended up with this...

It's kind of a mess on the firewall, but there is only so much I can do to make that many wires look decent.

It was at this point that I realized I didn't do anything with the original transmission/starter wire harness. So I removed the original starter power and ground from that harness and re-wrapped it. This leaves me with the reverse light and the signal wire for the starter.

Installed:

 

[bkrathwohl]

I test fit my radiator fan and turbo to see what kind of room I was working with. Looks like there will be plenty.

I cleaned my windshield washer reservoir. I really wish there was a way to make that clean white again, but it will just turn yellow in the future anyway. For now, at least, it is clean yellow.

Some more things arrived:

I mounted the coil pack first.

As I have an alternator relocation, which is right in the way of where the ignitor mounts, I decided to make my own bracket. This was easy using the stock bracket and trimming the excess off.

Nice and cozy in it's new home.

Next up was the front brake lines. I have the rest of the stuff coming to complete my entire braking system, more on that when it arrives.

I was amazed at how easily the ECMTuning flex fuel sensor wiring was to get set up. They send you a pre terminated two pin harness that you just pop into your ECMTuning SD cable.

Plugged in and routed next to my body harness to engine harness conector.

Then just ran to the firewall for now. I will definitely need to tidy all of this up once everything is installed. Notice the fuel line as well, the rest of my fittings arrived for me to finish up that project.