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Street Build ITFLYS - 1Gina2G

Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
China turbine housing work:

Porting the waste-gate flapper hole:
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I used some copper gasket spray on this washer I found. It is sticky when dry and it helped to hold it in place while I trace it with a sharpie.
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Blue line as a guide, probably won’t be able to go as big.
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Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
Here is what I came up with to clearance the turbo cartridge for the larger “upgrade” thrust bearings:
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Just need a little room - non load bearing
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Finally time to assemble and torque the rotating assembly
Heat shield
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bearing 1
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Not shown is the retainer clip installed on the turbine shaft.
bearing 2
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Clearanced the housing for the 1st thrust bearing
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Not shown is the o-ring installed, and the 2nd thrust bearing with its retainer clip
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Tricky part is getting the thrust bearings aligned as they were balanced
Under the compressor wheel is a c-clip
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Spins nice 👍🏻 😊
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Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
Hot side, a hole is ported, a plan is thwarted
This is the new hole, bigger.
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Mended vs melted
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but here’s the thing - the actuator with the threaded straight shaft is loose at the welds to the bracket, so, looking at other options like modifying the old one
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Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
Old part plus scrounge good parts from broken parts, and some die cutting of new threads on the actuator rod, gets it done.

To eliminate the rod going off in the wrong direction for this E3-ish turbine, I had to tweak the WG actuator bracket, and add spacers under one foot
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Then, I made the rod as straight as I could with some work in a vice and a hammer. The old rod end was cut off:
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Next to cut some 6.0mmx1.0 threads so I can re-use the adjustable clevis. I started with 6.3mmx1.00 for the initial cut, then followed up with 6.0mmx1.00 for the final cut.
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Now, screw on the lock nut and clevis with a little pre-load to hold the flapper shut well. e-clip and ss washer to hold the pin.
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Finally test with air and it works smoothly!
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Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
OMG, the threads.
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The new hardware was not going in smooth, so I cleaned the gunk out with a M10x1.25 tap, and boy did they need it! The soot that came out of these threads was not helping.
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I did them all, and will assemble with fresh high temp anti-seize.
 
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CrackedDSM

Proven Member
1,918
592
Dec 17, 2009
Pensacola, Florida
OMG, the threads.
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The new hardware was not going in smooth, so I cleaned the gunk out with a 8x1.25 tap, and boy did they need it! The soot that came out of these threads was not helping.
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I did them all, and will assemble with fresh high temp anti-seize.

Yeah, that used to be nuclear proof anti-seize. It’s been sitting so long I legit just forgot about it.

Good to see it’s getting new life and being treated how it should!
 

T bags

Proven Member
182
110
Apr 9, 2022
Newark, New_Jersey
OMG, the threads.
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The new hardware was not going in smooth, so I cleaned the gunk out with a 8x1.25 tap, and boy did they need it! The soot that came out of these threads was not helping.
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I did them all, and will assemble with fresh high temp anti-seize.
Looks like fun times
That k&w is an excellent product
How many turbos has that table seen 🥸
 

Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
Apparently Oakland has an entire strip of auto service and muffler shops right down the block!
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Flap disked the down-pipe section to death - prep for zinc spray.

While stripping I noticed a spot that was leaking. got a quick weld on it:
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Also, got the EGT probe plug tacked onto the manifold to prevent accidental backing out and shooting a hole in the hood (LOL)
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That clears the way for final prep for installation
 

T bags

Proven Member
182
110
Apr 9, 2022
Newark, New_Jersey
This time, I’m going to try copper spray on all the ss metal gaskets.
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All torqued to spec - slowly and evenly.
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It is supposed to be top quality I used to make those way back on the small block Chevy Progress is looking good
 

Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
This GSX is technically equipped with a turbo again. Very pleased with the result.

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Water return line hooked up
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I bolted up the O2 housing then lifted the assembly into place and started the manifold bolts by hand, then torqued to spec

The most annoying moment in the whole install was getting the gasket aligned and bolts installed for the oil drain. Needed to use a roberts bit driver to align one hole so I could start a bolt in the other
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I used compressor air to actuate the waste gate, and it still moves smoothly! I never realized how close to the front motor mount the WG actuator sits until now.
 
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Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
o2 sensor, then lower heat shield, PS pump bracket back in place (removed to torque manifold bolts) oil line… hmm wait I have a plan.
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I want to put clean oil into the turbo, so while I have the timing covers off, and the belt undone, I changed the oil and filter, then turned the pump until clean oil pumped out the supply line.
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next hook up the supply line and pump some more
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Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
Primed, and confident the pump will make pressure, Its time to put the timing belt back on for real, tension it, Mid cover on, lower cover on, THEN the pulleys with belts.

Stopping here for note - an allen wrench to align water pump and two stacked pulley in one bolt hole, makes it quick to start the first of four bolts. The space where the engine mount sits gives good access

Crank pulley torqued on, belts snugged up. alternator dressed, mount harness plug bracket bolted to mid cover.
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A/C belt pulley tensioner snugged up, And the motor mount
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Starting to look at bringing back in the radiator.
 
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Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
Moving along
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Nice shot of the new shields
And the radiator is back - its 2022 and I’m still having fan clearances to address.
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Wrapped up the evening, with a funnel just waiting for coolant. Almost all the parts for the engine are hooked up.

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T bags

Proven Member
182
110
Apr 9, 2022
Newark, New_Jersey
Moving along
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Nice shot of the new shields
And the radiator is back - its 2022 and I’m still having fan clearances to address.
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Wrapped up the evening, with a funnel just waiting for coolant. Almost all the parts for the engine are hooked up.

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A lot of progress
 

T bags

Proven Member
182
110
Apr 9, 2022
Newark, New_Jersey
In search of a coolant reservoir- i see the cracks starting to show in the original.
Do they make an aluminum one for the dsms? Similar to this one

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Hmm, it didn't fire. Sorta wanted to fire, but it was pushing back agains the starter. Something related to the sensors I bet.
Engine grounds?
 

Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
Do they make an aluminum one for the dsms? Similar to this one

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Engine grounds?
I have not looked for alternatives to stock yet. I think the stock one is fine, has a 95-96 specific sensor.

I’ll know more when I switch back to the blacktop 1g sensor that has been working.
 

Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
What worked before, will work again
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Installed
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Down pipe installed
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Ready to fire again
 
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Justin DuBois

Proven Member
770
588
Aug 15, 2019
Oakland, California
1G CAS back in place, and it runs! and it sets off the smoke detector!

That answers a lot of questions. Valves must not have been bent in the process, and the mechanical timing is correct. ECU repair seems to be good so far.

This is good enough to put wheels on and turn the car around.
 
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