99 Spyder GST 65K

[AccidentalDSMr]

What's up DSMTUNERS! Long time lurker, first time poster here. Huge thanks to this forum for serving as my primary source of guidance and knowlege. I've actually been lurking around this site for almost a year, trying to learn as much as I can. I bought the car last December. I originally had a simple plan: Upgrade the turbo to an Evo III 16G. That was all I wanted to try and do and boy has this turned into an adventure! I'll list my mods at the end of the post. I've had some help along the way, and met some new folks, but today I finally just went for it and dug into the car for the (and my) first time. I've had it tuned, and it's running "pretty" good (rich), but there's a lot of the truth to that old adage that if you want something done right...you just gotta learn to do it yourself. Plus I think I have just about driven all my mechanic friends, new and old, crazy with questions at this point. I am going to try and replace a melted fan so I have removed the radiator. Never done that before! While I was in there I started looking around and came across a gasket that looked kind of funny. Anybody know if this thing is shot? I actually have a million questions and I think I have come to the end of the knowledge that I can gain from just reading. I'm not sure how much I can contribute at this point but I'll try and help out where I can!

Here's what I got:

99 GST Spyder w/65k Original Miles
MHI Evo III 16G
OBX POS Tubular Manifold that doesn't fit right but is working (one little leak)
Tial 38mm Wastegate off manifold
Tial Recirculating BOV
ETS Street Intercooler
FIC 850 Injectors
Fuelab AFPR and Filter
Supra Fuel Pump
Innovate Mtxl Wideband
Glowshift Boost Gauge
DSMLINK V3 FUll
ARP Manifold Studs
ARP Head Studs
Full 3" Exhaust
Mishimoto Radiator
Flex A Lite Fan
All new Gates Racing belts
New plugs and wires
A desire to learn

 

[AccidentalDSMr]

A little more background:

All the install work has been done by people other than myself. I figured I could just have the stuff put on there, have it tuned, and that would be that. This did not work out exactly as I had planned. After everything was installed and the car was running pretty good, I took it to have the rear quarter panel painted where the clearcoat had failed. When I got the car back from the paint shop, the fan was melted. SO...yeah. That's where I'm at right now. Going to try and replace the fan myself. I think I got this...I got the radiator and fan out, so I'm pretty sure I can get them back in. Once that's done, I still need to address the exhaust leak at the manifold and figure out a way to manage the heat. I do have a blanket for the manifold, but I'm worried about the alternator. Like I said...quite an adventure! I'm optimistic that I can learn a lot and hopefully get this car stable (not constantly having something break)

 

[crash89]

Taking care of maintenance first like you're doing is what is going to keep this thing from breaking all time time, so for that, good job!! That gasket does look to me to be junk, Id change it. I wouldn't really worry about the alternator, my 3'' exhaust comes within a half an inch of mine and its been just fine for 3 years. What exactly melted on the fan?

 

[Type1DSMr]

Your turbo to manifold gasket is shot and needs replaced asap.

 

[AccidentalDSMr]

Thank you guys so much for replying. Ya I kinda figured when I saw it that it might be toast. The fan was actually one of 2 aftermarket flexalite 12" fans. It was originally suggested that I get the dual fan, but I couldn't find that one anywhere online so the guy said to just get 2 single 12's. It was one of the four bushing pieces that hold the blades in place that melted and caused the blades to go out of alignment. They were fine when it was warm but once the car cooled off it became noticeable. The next time I cranked it there was a whole bunch of racket up there and upon investigation I found the culprit. I was actually able to kind of bend it back into shape and took it out for a drive last night. No noise and the car wasn't overheating so I figured everything was fine....until....the turbo just completely stopped working. I could hear it spinning when I gave it gas but it wasn't building boost. It would dip into vacuum but wouldn't boost much above zero. This literally just happened last night so I'm still a little bit like wtf but I have a new fan on the way (I found the dual one) and when I took it apart I found an intercooler coupler with evidence of leakage so I tightened up all the clamps. Honestly I'm not sure what is going on with the turbo though. Maybe that gasket? I couldnt find any other hoses that had popped off so I'm thinking it has either got to be the coupler that was leaking or that gasket. Thanks again for replying. I know I'm probably in over my head here, but sometimes you just gotta jump in feet first!

 

[AccidentalDSMr]

Here's that melted spot on the fan tho.

 

[crash]

First off, nice work on going after this stuff yourself and wanting to learn it. Make sure you do plenty of research and double / triple check before pulling stuff apart and before starting the car after putting it back together again...from experience... You can download the service manuals for your car from the site if you haven't already.

Agree with your mani to turbo gasket being shot. It really should not separate like that. This could likely be the exhaust leak you're hearing. On your lack of boost, you're on the right track checking the IC pipes. You have a boost leak, and from the sounds of it a pretty big one. You'll need to do a boost leak test. Plenty of info on building your own tester and doing that on here.

I'd also question your shop about why the car got hot enough to start melting parts while they were painting it. The car does not need to be running while they are painting it and it's not like they have to do a test drive or anything. Not trying to knock your shop but I'm skeptical about giving my car to someone and getting it back with something wrong.

Good luck with your schooling and welcome to the club!

 

[AccidentalDSMr]

One word: Joyride. But what can I do y'know. "Wasn't us!" Oh well...live and learn. I'm not the type to raise futile hell. It would have happened eventually anyway and it motivated me to get my ass in gear and start trying to tackle things myself, so maybe it was a blessing in disguise.

Thanks so much to everyone for replying...it really means a lot to a guy who is basically in the dark here. Well maybe not completely...because I have been reading and studying pretty diligently for the better part of the last year.The amount of knowledge on this forum is pretty insane.

So my plan for now is going to be to look into replacing the gasket (no idea how to do this) and installing the new fan. Then do the boost leak test. Word.

 

[chrysler kid]

Why is there a hack saw sitting in your engine bay next to tin snips and wire cutters

 

[AccidentalDSMr]

I was about to get medieval on that mofo. But then I came to my senses and made a profile here.

Actually I thought I was going to have to cut the intercooler piping where the coupler had leaked, to make it fit better, but it turned out to be okay. Tin snips and wire cutters were for cutting zipties.

 

[Dragnous]

I was about to get medieval on that mofo. But then I came to my senses and made a profile here.

Actually I thought I was going to have to cut the intercooler piping where the coupler had leaked, to make it fit better, but it turned out to be okay. Tin snips and wire cutters were for cutting zipties.

You should create a Car Profile also so you can keep it up to date than you will not need to explain everything each topic.. plus we can keep tabs.

 

[Mauispyder]

Generally recommended to get 8 new turbo to manifold washers and 4 new turbo bolts. Soak your bolts in PB blaster for a few days before wrenching on them. If you can spray them from the bottom that'll help as that's where the threads are. I got three of four off without breaking. I'm told that's pretty good. If they break it'll just be in the turbo, consider lining up someone to drill it out. Also nickel based antiseize recommended on exhaust and turbo bolts.

 

[Drop Top Road Trip]

Sorry your having troubles...but it's nice to have company in the Spyder Frustration game! Tried to remove a wheel today to test fit another and found the PO had used spline drive lugs...but didn't bother to supply me with the tool to remove them! Now I know why there wasn't a lug wrench in the trunk. One more hurdle...

 

[Dragnous]

Sorry your having troubles...but it's nice to have company in the Spyder Frustration game! Tried to remove a wheel today to test fit another and found the PO had used spline drive lugs...but didn't bother to supply me with the tool to remove them! Now I know why there wasn't a lug wrench in the trunk. One more hurdle...

Yea when i bought mine i feared that. I noticed when i got home it had those and at first I didn't find the 2 tools .... Found them under seat and I now Keep them in a very safe place.

 

[AccidentalDSMr]

Well the most ideal situation has presented itself. I finally got a call back from the one guy who I was hoping would help me out and he's going to take a day and help me install...an HTA68! This is awesome because I'll get to be there to "help out" (watch). Nah...I'm really good at grabbing tools and whatnot. We're going to change the setup a bit to try and bring down the heat. I'm stoked. I'm really not trying to build a 700hp race car...just get a little more power while maintaining as much reliability as possible. I'll post some pics when it's all said and done.

I think I ended up breaking 9 wheel studs when I put the wheels on this car! I did learn how to replace wheel studs on that day though. It's a strange car. I think it must have sat in the same spot for years. Such low miles. I actually drove about 500 miles to go pick it up after searching cars.com daily for almost a year.

Anyway thanks again to everyone who has posted here. I'll make a profile page and keep you guys updated!

 

[AccidentalDSMr]

Changed the gasket and replaced the melted FAL fan with a Perma Cool. Got everything back together. It runs!