2g build

[triston2469]

very nice build man. I must say i am very impressed and the car looks amazing. that is something along the lines of what i want to do only i have a 1g. but on the bright side i am gonna buy a new motor and build it while i still drive mine around till i am able to finish the motor and can install it.

 

[952g63t]

Thanks Triston,

That's a good plan. Nothing wrong with having something to drive while you build up your new block. I may do something similar after I finish up this build.

Installed SS brake lines today. Huzzah for vise grip pliers!

 

[952g63t]

Had an all night-er with the DSM. Finished all the brakes, installed transfer case, installed exhaust, and finally laid her down on all four for the first time since she got here.

Tomorrow Ill be making some final tweaks to a couple things in the engine bay (loose coolant hose to throttle body) and taking her for a spin around the block (hopefully).

Pictures and maybe a video soon.

 

[952g63t]

Since my last post I've been dealing with idle issues. First it was my MAF, replaced that and it was idling perfect. Next day I installed a battery and MBC and broke my knock sensor wire (harness end) so I hard wired it in (wrong the first time) and finally managed to get it running "normal" again. Then last night it started to idle surge, and then today the accelerator started to rev and hold at 3k+ by itself until I feathered the throttle to make come back down. So I took apart my throttle body completely (like I should have the first time) and am soaking it in brake cleaner, minus the gaskets. All sorts of black sh*t came out of it when I sprayed it out.

Funny thing, when I disconnect my MAF it still idles almost perfectly, though I am sure my old MAF was bad, I wonder if the used replacement MAF I have now is going bad or is also not 100%. Tomorrow should be nice so Ill be turning wrenches all day.

Only thing I am waiting on right now is a replacement caliper for my front brake. I had one bleeder break off and tried drilling/taping for a new bleeder which I thought was successful, but after threading the new bleeder it would not hold fluid in, so rather than drill/tap another size larger I just opted to get a new caliper. Damn replacement bleeder was tight too

 

[turbolover10]

Looking good so far, keep it up! Love those rims.

 

[952g63t]

Thanks turbo.

Got my throttle body cleaned up and back together today. While I was there I decided I needed to tidy up my wire harness, big mistake. Unfortunately now it wont start again. I'm almost certain its something to do with the harness. The damn thing is so beat up, I am really considering swapping it out. Seems like every time I touch it another wire breaks. On the bright side, while frantically checking fuses I noticed one that I hadn't noticed before. The 100amp alt/choke was bad, replaced it, still no start but my heater fans work now.

Anyone have a good wire harness they want to donate?

I know its getting fuel to rail, but not sure if its a spark issue or injectors. Gotta be one or the other. I may try a OBDII scanner tomorrow, might get lucky.

 

[952g63t]

Found the new culprit. A broke crank position sensor wire on the plug. Is it possible to reconnect the wire to the plug without soldering? Pretty sure I read somewhere that this would cause a no start condition.

Edit: That was it...

Installed my boost, oil pressure, and wide-band. I don't have emulation/simulation so I installed the sensor on the rear 02 bung.

All the gauges light up and seem to work great, but I am showing a VERY lean idle on the wide-band. Which makes sense because it stalls out. Also the exhaust manifold started getting much hotter than usual. When I do rev it, the wide-band fluctuates normally depending on the rev. I didn't like seeing the manifold getting so hot so I shut her down after a few minutes.

Edit: I have a leak at my 02 housing where the exhaust mounts up to it. Gasket on order, along with some new bolts. I'm sure its contributing to the lean afr.

Oil pressure is good.

I'm wondering if my knock sensor is still wired wrong. I need to figure out how to properly fix the connector. Guess I need to order a replacement sensor and get a harness clip somewhere. So frustrating to be so close to drive but not know whats wrong.

 

[952g63t]

For those who are following, I had been laid off and had to put the project on hold. Good news though, project is getting back on track. I have a pile of parts I need to install soon as the weather gets better.

Stay tuned...

 

[952g63t]

Replaced the broken crank position sensor and turned her over. Still no idle with MAF connected. Unplugging my MAF seems to point to an issue with the second hand unit I have installed.
My exhaust manifold started spraying steam out of a small crack I had not seen before...

On the bright side, while I was checking my coolant temp sensor the last little wire hanging on to the plug broke. Upon starting the car again my radiator fans kicked on for the first time!

 

[952g63t]

Loads of parts to install, including one very highly anticipated knock sensor. My living room is starting to look like a parts store.

(1) Cylinder head "built" by ATX Motorsports
Sparco seats (black) and rails
factory replacement carpet (black)
rear control arms
3-inch stainless down-pipe (still need to get (2) 02 bungs welded in)
transfer case seals & hardware (leaked fluid out of the output shaft?)
stainless 4-bolt 02 housing (hint hint...)
TiAL wastegate (10 psi spring, hint hint...)
Some other misc. parts NGK 7's etc.
And last but definitely not least, a new Precision 3431E turbo.

Still need to get:
Exhaust manifold
Test pipe/resonator (current Apexi N1 was hacked together, keeping the Greddy exhaust)
Oil feed/drain lines & other misc. hardware.

Eventually:
ECMLink
Fuel pump/re-wire
Injectors
Intake manifold

I will be running about 10 psi until I get a good base tune. Even then its only getting some modest adjustments until I am comfortable that things are running well enough to up the boost any more.

Will update w/pics soon

 

[GofaST4life]

Awesome build man!!

Get some current pictures up.

Have you figured out the rest of your issues.?

 

[952g63t]

Thanks gofast,

Won't really know until I pull my cylinder head. My timing was spot on from get get go, so the only thing I am a little concerned about is what possible damage (if any) occurred while it idled with a bad knock sensor. Soon as the weather cooperates Ill know more.

 

[952g63t]

Just drained my coolant and oil. No sign of oil in coolant & oil looks normal. Ill post some pics in a few. I believe what I have is a blown t25.

Edit: No oil or coolant in the exhaust ports on the head. Found a little bit of coolant residue in the ic piping. No shaft play on t25. Ill be changing the oil like a mad man for the first 500 miles or so. WIX oil filters ftw...

 

[952g63t]

Pulled the head today, everything checked out ok. Not sure how common it is but my t25 was pushing coolant into my intake/IC piping. Waiting on a head gasket and some other odds and ends including a tubular exhaust manifold.

Decided to upgrade the PTE at the last minute. Went with the 5976E. This one has the billet wheel 620hp?

 

[952g63t]

Finally got all my hardware together and was able to assemble/mock up the turbo. Everything looks and fits pretty well. Hopefully I can get her back together soon.

 

[952g63t]

Busted my ass this weekend. Pulled block & trans, installed new clutch and dropped block and trans back in. Installed cruise delete cable, which was nice because it wasn't a PITA. Finished installing seats. Weather permitting I think I can button up the new head and turbo install next weekend. Hopefully I have all the wiring mess sorted. Next major upgrade will be ECMLink.

Had a hell of a time sourcing a 3" midpipe to frankenstein together with my exhaust. I ended up going with the SRS kit. Looks like I'll have to ditch the GReddy though. Sucks because I really like the way it sounds. Just don't think it will fit right.

Throttle back from Throttlebodys.com

 

[952g63t]

Last night in the middle of my head swap I had a chance to inspect the intake manifold seal to my old head. Low and behold the gasket was the wrong size. This of course was creating a huge vacuum/boost leak and would explain, well pretty much everything... Each runner rim had a 1/4" black streak leading to the outer edge. WTF

I had gotten the gasket with the car originally and ASS-U-ME-d that it was the correct size and threw it on. Now that I look back, I remember looking at it thinking how odd it was that the gasket didn't line up with the runner inlets completely but still lined up with the bolt holes. Wow, just wow...

I finished the head swap with no hiccups. New ARP's, a Mitsu OEM head gasket, and an intake gasket were on last night's menu (been watching too much Jafro). To my utter astonishment the new intake gasket fit perfectly. Those ARP's torque so much smoother than stock head bolts.

Edit: Forgot to mention, also installed a braided ss clutch line.

 

[952g63t]

I attempted to mount my exhaust manifold/turbo the other day and ran into a fitment issue. The center housing comes into contact with the block where the front balance shaft bulge is. Of course, it was because of a single piece flange adapter I used that pushed the turbo half an inch too far down. Thats what I get for trying to piece together a stock manifold flange to a t3...

So I broke down and shelled out for a quality piece from Punishment Racing. Think I got the last one they were offering on sale. This should solve the fitment issue.

 

[952g63t]

Still waiting on this manifold from PR. Waiting on this thing for almost 4 weeks now

I've been trying to take care of other things until the manifold arrives, but really don't have a ton left to do. I still need to install my drivers side door window, and finish the interior trim. Was going to do the 2gb bumper swap but decided to keep the original look with the low rise spoiler and smiley bumper. Did order some new halo projector headlights w/black bezel. Oh, and got an O2 bung welded into the new DP yesterday for 20$.

Pictures coming soon.

BTW, anyone still following this build? NO FEEDBACK IN AGES!
I know, its not a 5k forged engine build for 9's... ...yet...

 

[PrimerPLus]

Yep. Looking good.

 

[952g63t]

Manifold arrived today. Holy **** this thing is amazing.

 

[952g63t]

Everything fit pretty well minus one radiator fan. I may try and mount it to push from the front. Finished getting the belts on and the exhaust mounted. Still need to finish wiring up everything. Down pipe is close (not touching) to my oil filter. I will probably change over to the smaller filters, or ditch the sandwich adapter and run my oil pressure line off of the OFH somewhere. If all goes well tomorrow I may be able to take her out for the first time. Fingers crossed.

 

[PrimerPLus]

That looks amazing brother. That thing is going to be beast.

 

[952g63t]

I just hope no other nasty surprises pop up tomorrow, FML.

 

[MakeItHappen]

I just want to see this thing going, I read through it all and it seemed like you were gonna have it moving like today and then something else showed up for you, good luck