Lancer Evolution III Intake Manifold

[white97gst]

Sold to DSMunknown. Thanks man. I'll ship it out tomorrow. I'll email you with the tracking info.

 

[sd_ff22]

Well guys,
I did it. I have an early day so there will be more info and WAY more pics tomorrow. I took pictures at almost every step of the way. 132 in all, including pics of things I had to fab up along the way and last minute stuff. I have been out for a drive, but I am still tracking down boost leaks so I don't have logger data just yet. Turns out I have a coupling that leaks at 5lbs. Changed that out tonight so I will have better results tomorrow.
Brought to you by Killian's Irish red.

REP ME.

 

[white97gst]

Damn. I didn't realize how much shorter the runners really are until I saw your pic of the 2 side by side. Kinda makes me wish I hadn't sold my 2nd one so cheap. Looking forward to the rest of the pics. Thanks for taking the time to photograph the install.

 

[white97gst]

BTW, what kind of STB is that?

 

[DSMunknown]

Yes, thats just bead blasting it. Am thinking I may get it powder coated in clear to protect it & keep it looking this way

Just for future reference, I saw this product on the show "My Classic Car" and was pretty impressed, even though I know very little of this process. Looks like a solid product for a great price for those of us just getting into the powder coating scene.

 

[DSMunknown]

I took pictures at almost every step of the way. 132 in all, including pics of things I had to fab up along the way and last minute stuff.

Sounds like me when I'm doing an install guide.

Dan, what have you done in terms of the TB? If you're still using the old 2G, it would be interesting to see the gains anyways, but I can't wait till you get a larger one (unless of course you already have). Keep us posted!

BTW, my third one is on it's way.

EDIT: Nevermind. Just checked your profile and you've got a 1G TB. Awesome.

 

[sd_ff22]

I'm at work right now and all i want to do is go play with the car!!
The strut bar is a DC sports carbon steel 1 (CS1). they make a CS2 double bar brace wich I have on the rear. Looks great, but only the CS1 fits the turbo eclipse front because of the MDP sensor.(that I don't have to worry about anymore!)

Anthony-
The throttle body is a 1Gt that I rebuilt and replaced the shaft seals in. I also moved my FIAV housing from my 2G TB over to the 1G because I didn't want to take the chance on the older one being bad. I am having no idle surge or any idle problems at all for that matter.

 

[95CarbonEclipse]

WOW! It looks great! How long did the install take (including taking all the pictures and everything)? I can't wait to see the dyno results.

What about the butt dyno now that you've fixed the leak (I'm assuming you have)?

 

[sd_ff22]

Derek-
There is a noticeable difference in torque in 5th gear. thats the best I can tell you till I get the last few boost leaks fixed and then I will get some lbs per min logs to see if it made a difference. I will also get back to the dyno as soon as I can.

Ok where to begin?...
Gathered all needed materials. Throttle body gasket set, and a can of permatex spray gasket(this stuff is AWESOME.) All standard tools, die-grinder, porting bits, dremel, 12in of 1/2in strap steel.

Lets start with I took a bunch of pics of how the vacuum lines route around the engine bay. I wanted it to stay stock looking. After I felt I had enough pics, I started with the upper IC piping and MAF+intake. Then I Pulled the plug wires and started stripping back the upper harness. After the harness I pulled the fuel rail. Next I pulled the TB elbow and used the double nut method to remove the TB studs.

 

[sd_ff22]

Now we have the BIGGEST BEECH I HAVE EVER DEALT WITH ON MY CAR.I don't know if its the shape or size of my hand or what, but It took me about 2 hours to get the bolts out of the bottom of the 2G IM flange!!! from them being blocked by other parts, to getting the wrench on but not having enough clearance to turn it I ran into problems. The stock runners drop so steeply that you can not fit a socket and ratchet on(even the little 1/4 sockets.) So after running wire down through the runners and looping it around the wrench I finally got them all off and the manifold clear! I used an inspection mirror to look down my intake ports and checked my valves. They looked to be in good condition(clean anyway).
Next some comparison shots.

 

[sd_ff22]

Ok, I always do test fits to make sure there is nothing that gets caught on anything else. good thing too. I ran into a few problems that would have cause a lot more trouble if I hadn't caught them in the test fit process. I'll get to those in a minute.
My next order of business was to move the FIAV housing from the stock TB over to the 1G TB. There were two reasons I did this. First, I know that mine works correctly. Second The coolant lines are shaped differently on the 1G FIAV housing. Made sense to me. While I had it off I coated the FIAV gasket with RTV to make sure that I had a good seal. I had already replaced the shaft seals so this Modded 1G TB was ready to go!
Next I made brackets out of 1/2in strap steel for some of the emissions items that I had to move over. I Know they look bad, but once they were covered with other items you can't tell. The purge solenoid bracket was a pain because when I first tried it out the test fit put it much too close to the AC line. I re-bent it and lowered it and it fit great. the EGR bracket was just a 90* and bolted onto the rear brace mount. Now that the TB is in place, it looks like its installed as it should be...

 

[sd_ff22]

Next I started mirroring All the vacuum lines over to the new intake manifold. Easy stuff. This also allowed me to find a nice out of the way place for the MDP sensor. I needed a Manifold source and did not want it to show too much like the FPR solenoid line or the BOV line, so I installed a big "T" Into the brake booster line. This gave me The signal source for the Purge solenoid that used to be near the TB on the stock 2G IM. I also tee'd Into this for the MDP sensor. worked perfectly.

Then I Cut and drilled a small piece of strap steel to be an Igniter mount. Again, worked perfectly.

 

[sd_ff22]

I am going to say it again. Permatex is the Shat.
I sprayed 2 coats on the hondata heatshield and let it get tacky before putting it on.

Right here I'll let you all know that the rear brace was such a pain to get off the back of the 2G IM that there was no way I was going to put it back. I concede to Anthony on this issue. After tightening the bolts to 14ft/lbs and the studs to 26ft/lbs. the manifold feels DAM SOLID, and isn't going anywhere."where you going? Nowhere! thats right."


But thats getting ahead of things. I finished mirroring all the vacuum lines on the new manifold before installing. I wanted to make sure that there were no more interference issues. when everything looked good I put her in. The EVO manifold was WORLDS easier to install than the stocker was to take out. because the runners are much shallower, there was plenty of room to get the lower bolts in.

Next I started with the harness. I wanted to install the harness before the fuel rail because I wanted to hid the harness as much as I could. This worked out really well too. after I turned the injectors to the rear and stripped a bit of the cable shielding back(to extend a few sensor plugs) it worked great. I needed a bit more length on the MDP line and the coil pack line. I did not cut any wires, just the black cable shields that hold them. I was sure to re-wrap the harness so it was still sealed and strong. You can see in the last pic here how the coil pack covers the harness and the fuel rail stands out over the injector plugs.

 

[sd_ff22]

I started putting all the surrounding items back together. this included moving a few sensor mounts and plugging things back in. Easy work.

For the Throttle body, I again used permatex on the gaskets. this went together easily, as many of you know. I looked to see how the 2 throttle bodies where routed inside and hooked up my vacuum lines accordingly. A2 and E have a short piece of vacuum line running between them. My BISS was set at 1 full turn out from all the way in. This has caused no idle issues or CELs and runs fine. Also of note, my NGK plug wires reached the EVO coil pack with plenty of length to spare. I am sure that I've forgotten a bunch, but It was a fun install and a good day.
All in all the install took me about 10 hours. I probably could have done it faster, but I was enjoying the install and taking a bunch of pics too.
I'll get more info for you all as I get it, and I will be back at RRE to dyno as soon as funds allow.

Thanks to all you guys! I Know a lot of this info I got from us all brainstorming. Couldn't have done it with out you.

 

[95CarbonEclipse]

Great write up! Thanks Dan.

I NEED THAT EVO III COIL PACK so I can install my IM!!

 

[sd_ff22]

Did you PM 98evoIIIpower?
I thought he was going to sell the one he had to you?
Honestly it would have been a REAL pain to try and modify the 2G bracket to fit. plus this one looks great with the new IM.

Oh and PS,
I went for a 1.5 hour drive today.
Got no CELs, no idle issues and when I Got back to work I popped my hood to feel the intake manifold.
I could full hand grab the top of it and it was barely warm! Thats even with a non vented stock hood and everything else underthere was hot as hell! I don't know if it helps with power, but that hondata heat shield sure does isolate the intake manifold from conducted heat!!

 

[daren_p]

Did you PM 98evoIIIpower?
I thought he was going to sell the one he had to you?
Honestly it would have been a REAL pain to try and modify the 2G bracket to fit. plus this one looks great with the new IM.

Oh and PS,
I went for a 1.5 hour drive today.
Got no CELs, no idle issues and when I Got back to work I popped my hood to feel the intake manifold.
I could full hand grab the top of it and it was barely warm! Thats even with a non vented stock hood and everything else underthere was hot as hell! I don't know if it helps with power, but that hondata heat shield sure does isolate the intake manifold from conducted heat!!

Dan, did you hook the factory coolent lines back up to the TB? If you did, thats good to know that gasket keeps the IM that cool even with them connected. I plan on running one as well (well the Magus one).

Don't say the stock 2g will be a pain to modify, I still haven't been able to pick up an evoIII one

 

[sd_ff22]

Daren-

Yes I did re-connect the coolant lines to the throttle body.
When I had both coil packs next to each other, I did not see a single bolt hole that would work for the evo IM without interfereing with something else. Not to mention that when you flip the 2G coil pack over, the plug wires will be out of order. It might not be a big deal to some, But I think that my setup looks great.

I actually have free time tonight so I will get a hold of some good vacuum lines and zip ties so I can fix those boost leaks.

Oh, when I was looking for a coilpack for myself I was looking at UK and australia EBAY. lots of evo1-3 parts there!
I even saw a coilpack or 2!

 

[95CarbonEclipse]

Did you PM 98evoIIIpower?
I thought he was going to sell the one he had to you?
Honestly it would have been a REAL pain to try and modify the 2G bracket to fit. plus this one looks great with the new IM.

I talked to him, but I haven't heard anything from him in a while. Last I heard he was going to get a paypal account of his own or something.

 

[EclipseAnders]

So,thanks to this thread I noticed that there is an EVO 3 intake manifold on my 2G that I bought
I still got to find an EVO throttle body. My question is: How did you guys do with the EGR? Is it plug&play?I don´t have the DSMlink so a CEL will be a problem for me if i skip the EGR on my Eclipse.
How will the Eclipse harness fit the EVO Throttle body?For example; how many wires are attached to the EVO TPS sensor? I don´t have the 2G throttle body so I can´t swap parts from there.
Here you can se a picture of my EGR valve(in the middle)

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Very thankful for your help!
BTW. My friend in Sweden has a EVO intake manifold from EVOIII for sale. If someone is interested,send me a PM

 

[white97gst]

eBay Motors: Mitsubishi Evo 3 Evo3 Throttle Body 4G63 DSM Eclipse (item 300221911834 end time May-10-08 18:39:20 PDT) This is my Evo3 TB. If anyone from here is interested, I'll ship it for free. Just enter $10 in the shipping discount box when paying through Paypal. If for some reason it won't let you, tell me and I'll refund the $10 for shipping.

 

[white97gst]

Sold!

 

[DSMunknown]

For some reason I had a hard time tracking down a vendor that sold the Hondata heat shield gaskets for the DSMs. For those who are wondering where to get one, Horsepower Freaks currently sells them.



https://www.horsepowerfreaks.com/pr...-Talon/Hondata/Engine/Intake_Manifold_Gaskets

 

[sd_ff22]

Lightning Motorsports - Hondata Heatshield gasket 95-99 Eclipse 2.0T -

Anthony beat the price by $3 but this is where I got mine from.

Is anyone interested in my airflow data, or are they waiting for dyno results?

 

[DSMunknown]

Dan, do you really have to ask?