Street Build ITFLYS - 1Gina2G

[Justin DuBois]

Whatever that is on the bar it isn't stress fatigue. Looks like scratches from your vise. Bar looks good. I don't see a problem. Put a breaker bar on the crank. Use a socket not the square hole.

No, you don't understand - The marks showed up while using a breaker bar in opposing force. I watched them appear. - It was freaky.

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[Justin DuBois]

A success!
I cut the bar for the sprocket in half, and made another matching set of holes and notch to make a double thick tool. 16 inches is a lot less leverage. Now that the sprocket tool is shorter than the breaker bar, I used the table edge to hold it from rotating. Finally, using the 22mm socket on a 1/2” breaker bar, I hold tension on the bar and then a whack on the handel with a sledge to provide shock force. That did the trick for this motor.

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This is the in car backup plan:

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[Justin DuBois]

With the crank bolt loose, I can now mock up the Kiggly sensor install:

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[Justin DuBois]

Putting it all back was equally instructive, The 16” crank pulley tool is very similar in length to my torque wrench. This made it easy to push/pull the tools together until the torque setting was reached, which topped out at 105nm, which is below the specs. I think I’ll need to find a slightly bigger wrench! good to know.

I reacquainted myself with the 1990 DSM engine section of the service manual. A real nice manual I have to say. So glad to have this in print.

I think it is time to get at the engine in the car. The water pump is now leaking after removing the alternator bracket.

 

[CrackedDSM]

Did you ever end up finding a good red stripe/non-mitsu lettered spark plug cover? I've been scouring for you and can't find a new one anywhere. Mitsu lettered ones are still made though. Lol.


Amazing attention to detail though. Keep it up!

 

[streetraceboi]

Did you ever end up finding a good red stripe/non-mitsu lettered spark plug cover? I've been scouring for you and can't find a new one anywhere. Mitsu lettered ones are still made though. Lol.


Amazing attention to detail though. Keep it up!

I got that taken care of

 

[CrackedDSM]

I got that taken care of

Nice. Can't wait to see what you do with it.

I wish I was better at injection molding plastic. I'd make a bunch of new ones and sell them. Still drooling at the thought of a reproduction of the mitsu one but with an Eagle symbol and "Eagle" on it. Alas.

 

[Justin DuBois]

3/4” impact removed the crank pulley center bolt in the car no issue, but I found the crank pulley bolt washer wedged into the harmonic balancer, and the parts holding it in came off the timing gear! ouch.

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I think the washer was installed flipped, and the washer is tapered, so the thick part got pressed into the gear, cracking off the centering ring. I was lucky this didn’t cause a bigger issue.

Now I’m dealing with getting the timing cover out of the way!! 1Gina2G issues

 

[pauleyman]

I think the washer was installed flipped, and the washer it tapered, so the thick part got pressed into the gear, cracking off the centering ring. I was lucky this didn’t cause a bigger issue.

Now I’m dealing with getting the timing cover out of the way!! 1Gina2G issues

No. That lip is part of the crank gear. The washer isn't tapered as far as I know. Looks like the lip just got torn off. Corrosion perhaps?

 

[Justin DuBois]

No. That lip is part of the crank gear. The washer isn't tapered as far as I know. Looks like the lip just got torn off. Corrosion perhaps?

Yes, I'm sure some corrosion affected this as well. It has been on the car a long time.
Yes, the centering ring that WAS part of the timing sprocket is a crumbled remains collected from the harmonic dampener.
I have two washers, and they both are slightly tapered on the outside edge. Could be due to deformation under pressure? maybe? but I will be putting the narrow side against the replacement timing sprocket.

 

[pauleyman]

Yes, I'm sure some corrosion affected this as well. It has been on the car a long time.
Yes, the centering ring that WAS part of the timing sprocket is a crumbled remains collected from the harmonic dampener.
I have two washers, and they both are slightly tapered on the outside edge. Could be due to deformation under pressure? maybe? but I will be putting the narrow side against the replacement timing sprocket.

Now you've got me interested. In 30 years I've heard no mention of this.

 

[Justin DuBois]

One is more tapered than the other, but both tapered.

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[Justin DuBois]

To get the timing cover off, I needed to get the AC tension-er, AND compressor pulley out of the way. Similar to pulling a motor, I hung the compressor still plumbed from the firewall with zip ties.

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Even still, I cracked some bits at the top of the cover trying to get it past the motor mount. This cover is not going back on. It is - um - Fugly.

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Melted, warn, missing parts, cracked. I didn't realize that the one in the car was the "bad" one and the spare is nearly perfect. It has been suggested to cut the lower cover into two parts. I'm seriously considering this.

Old parts removed:

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[Justin DuBois]

a little time today
ECU is back where it goes.
Crank tensioner arm removed
Silent shaft crank gear removed

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Spare water pipe removed for PC
Spare PS pump block bracket removed for PC
Spare Harmonic Dampener pulled for strip and paint
Fugly Timing Cover - Cut to mock up a mid/lower cover modification

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Test Cut

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I will improve this now that I can clearly see what it will take to clear the tensioner pully.

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[Justin DuBois]

My 12 year old son (in art school) was inspired by the shape of the T-belt covers, and asked me to air drop him a picture of it. This morning he presented me this drawing, and asked for more pictures of car parts:

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I like where this is going.

 

[Justin DuBois]

Cleaning with mild soap and water, then removal of the water pump. Snow brush and tooth brush did pretty well.

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The spare timing cover cleaned up very well, with brake cleaner on a paper towl, then some mothers ceramic gel to protect the plastic:

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[Justin DuBois]

Cleaned up, and parts starting to go back on:

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Kiggly crank sensor install

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[Dericsh]

My 12 year old son (in art school) was inspired by the shape of the T-belt covers, and asked me to air drop him a picture of it. This morning he presented me this drawing, and asked for more pictures of car parts:

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I like where this is going.

Nice work!

 

[Justin DuBois]

Needed to make a couple 3/16” holes in the back timing cover under the motor mount.

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Wiring harness routed and attached

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[vanilla gorilla]

Clean work. I dig it

 

[Justin DuBois]

Water Pump installed

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[Justin DuBois]

Sensor cable routing with the Kiggly is no joke. there are two spots that are critical to prevent belt vs wires contact, on the belt between the crank and the tensioner pulley. The other is on the belt between the idler pulley and the oil pump. I found flipping the orientation of the zip tie on the tensioner post tends to push the wire away from the belt towards the back of the pump casing.

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Which allowed me to move on to installing more timing components.

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[ryztriumph]

I've really enjoyed watching this build, and I cannot express how much it means that you are still keeping up with your build thread. Thank you!

 

[Mello]

Running stock cam gears?

 

[Justin DuBois]

Running stock cam gears?

At the moment, yes. 1G cams, and stock gears are bullet proof. Endurance is important when you are building for Road Race corses where you are spending lots of laps with lots of revs with a b-shaft delete engine.

I have a set of AEM gears and Web cams on the shelf. Might install, might not.