It's Begun

[MikSchultzy]

Started teardown today.

Went with the "No Body" option.


And today, I tore out the intake/batter/FMIC. Took me ~2 hours to get this done (includes cleaning garage, finding tools, and bodyparts)
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Gonna start tomorrow on tearing out the manifolds (intake & exhaust), and then I'm going to begin working on getting the radiator out as well.

-------------------Day Two-------------------

Started today with doing this: radiator drain, oil drain...
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Then I went ahead and got rid of that other "Junk" in my way:
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Ended up finishing up with the Intake Mani today - didn't get it off, but got most of it disconnected. Need to figure out how to contortion myself to get the bolts that are directly under the intake.
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Some issues came up today that I ended up only getting 3 hours to work on her. I think I made some decent progress in such a short amount of time.

Hoping to get the intake off tomorrow evening, and then I'm going to start looking at what I've gotta do with the pullies/AC.
(Just a side note: those last two pictures are taken with just a droplight for light - hence the drop in picture quality)

------------Day Three-------------

Didn't get to do much tonight. Had to goto town to get gas and check on some tools - already stripped out two cheapshit sockets. So I picked up a bag full of my tools from work and bought some others that I didn't have (Impact sockets). Gonna pull the axels tomorrow and drop the DP to get it out of the way. Then I've just got the AC compressor and wiring to disconnect. Should be ready to pull out Wednesday. (Hint hint )

-----------------------------
No work done for a few days, time constraints and other issues popped up. Did get my toys home though:
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----------- Day Four (Of Work) ----------------

Started reading through the Evo Service Manual a few days ago, took the AC & Steering pumps off:
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Then I disconnected the oil cooler lines
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Then I got the LT and RT axles ready to pull off:
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I didn't have a slide hammer at the house today, so I didn't have a chance to pop the axles out.

My little boy decided to help me alittle today as well:
Keegan Help: 1 2 3 4 5

He was adjusting my crash bar.


--------------Day Five--------------------

Tore into her today, made some progress till I hit another knowledge block - I need some help with this one.

Anyways, got the Intake out:
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Then we went ahead and started to unbolt the tranny, and to fasten her up with the engine hoist:
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And one more: (there is one bolt in on this image that isn't visible due to very poor lighting)
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Anyone who wants to help is more than welcome to come down and BS. I'll buy the beer.

-------------------------
Big Update - I've lost track of days so here's the summery:

Got the engine out one Saturday with Otter's help. He was bold enough to climb up into the engine bay to stand atop of my slide hammer to hold the sucker down - then later to use a brace for hammering the other shaft. Ended up leaving the transfer case in the car (16). Pictures 15 and 17 are after the engine was out, and we got her leveled out onto a pair of spare tires. We pried on the TOB and f't id up more (though I didn't know till later). Made good progress. Sadly, the cherry bled all over the place, and left a rather big mess on my workbed. heh, heh, heh... Ended up "Shoeing" the engine/trans out together like the old V8 swaps.
15 16 17 18


So here's some more - rather random images.
19 has some head pieces that I've piled in a bucket to keep together/off the floor.
20 has a camo'd picture of my new turbo. :P
21 ....20 year old+ GoJo.
22 Super secret head, with old gasket.
23 Looking at the underside of the engine. Here's where I'll probably be starting my next bit of work - soon as parts come in. Rod bearings, rod bolts, main bearings, and main bolts.
24 Top side of the engine. Everything looked clean - other than the fluid everywhere from the gasket going, and then being tipped upside down. Probably going to do piston rings, but otherwise. *shrug*
25 SHINEY! Vikki polished the inner-cooler piping - all three pieces. I think I am going to have her shine my turbos as well. Bling bling.
26 Now that I am nearly finished, this is almost every part from the car. There's a small pile from the intake mani sitting under the car, the bucket/cam gears, and my radiator. Also my manifolds (@PPI), and the new turbo. Which I have started to disassemble.

Gonna have to start ordering more parts again. Heh, I was kind of hoping for the interest on the money I have sitting in there right now - guess not. :P

Still looking for a machine shop, I've got 2-3 here that I am going to be looking at. Also pondering about shipping it to AMS/JAM/Buschur, or another pro shop.

------------------Few Weeks Later--------------------

So it's been awhile. Been waiting on the machine shop - they were moderate in speed. I am thankful that they did my engine so fast, as they have a 10x10 room full of v8's to do. About a four week turnover time, including a delay on gaskets and pistons & rods (which I had to get new of, see alittle lower).
Anyways, on to what happened:

Had my head torn down (valves/retainers) and they installed dual valve springs with titanium retainers (31 32). I was able to sell off my old valesprings/retainers as well (yay me). They also decked the head (30).

Then they tore the engine down, and found that cyl 1 had excessive piston slap. Once they got everything out, I was called in and we checked things out. Piston 1 had more freeplay than I thought it should, looks like it could have been causing major problems down the road. The skirts on the piston are rather sharp as well. Jerry mentioned that it looked like it was shaving the walls of the cyl - and making it oblonged. The teflon coating on the skirts was also rubbed gone on 3 of the pistons, showing that piston 1 was a replacement piston from something else (uh-oh). Because of this, I opted to go with all new pistons. With that, I figured I might as well go with new rods as well. Ended up picking up a set of eagle pistons/rods (pictured in the engine: 29). Then they put everything back together, and needed gaskets. Which were sitting at home with the rest of my goodies. Oops. So two days later they got new gaskets. (P.S. I have rod bolts for sale now, make offer: (36)

Long story short, I had to bug them a few more times to get my engine done. I was trying to get it last week, but it ended up not being done till Wednesday (Halloween). Good stuff.

Back up to the weekend before Halloween though. Went up to Wayne's on Saturday, met him for the first time (good guy!). He had kidnapped my intake and exhaust manifolds, and it was time to take them back. Though he held my hotside hostage for a short time (and Vik and I boogied to Osaka, good eets). Had all three ported (though not coated: 27 28 33 34 40). Also picked up some beefy injectors (35), and left my throttle body (I blame you Joe) to be done. Hopefully I can see that by next weekend. (I had forgot about it!)

And then today, I got my clutch (39), flywheel (37), and tob (38) (kit) in today. I'm excited, because now I can put the transmission/block back together. (yay!)

Anyways. I put most of the intake together, sans t/b and 3 bolts which have to be put on later. I plan on mating the transmission and engine block tomorrow, though that depends on how much patience I have. If I all goes well, I should have her ready to go in Saturday. I plan on putting her in and getting the motor mounts on her, and the transfer case. Most of the time seems to be taken up by cleaning all the stuff because I honestly didn't take proper precautions to make it/keep it clean when I tore the car down originally. So I've been huffing WD/brake cleaner with the pole barn doors down. After about 5 minutes I'm going WEEEEEE~~~~~~~~~~...


--------------Fri Nov 02 ----------------------

Had full intentions of getting the engine ready to go into the car tonight. I suppose it is, except now I wont have a head gasket till the 10th - apparently they are made to order, and on backorder besides. Worse is that the 10th is the soonest that they can get one to me. Before that, I found out that the flywheel bolts they sent me were wrong, so I ended up using my old ones. Thankfully, I was able to tork them down to the right specs (98 ft-lbs).

Got the flywheel, clutch, and transmission on today. Had to fight with the TOB to get it changed out (didn't know how, figured it out though, and I feel S-M-R-T! ... . ...

Sadly, this means I wont have my car running as soon as I had thought.

If anyone knows of a gasket with the .020 overbore... (I was just going to use my stock replacement I got in the B-Word replacement kit, but it's not overbore'd) Let me know. I currently have Cometic "On the Way" for 89.99 (I think?), and would rather not spend much more than that though.


-------------Sat Nov 3-------------------------

Checked it out albit further. Joe mentioned that a stock HG would be OK (in that it fits .020 over), and can hold 1,000HP (or has fine before). I then checked alittle bit on the internet to see what I could find, and was confirmed that .020 overbores are OK to run stock headgaskets. So that's what I did.

With that being the case, I've got the engine ready to go into the car tomorrow. Ended up calling it quits tonight at 8 because my help had to scatter off (borrowed car).


-----------Sun Nov 4-----------------------

Interesting day today.

Baker and Rob came out today. Engine was pretty-much ready to go in when we were all set to go. Before Rob arrived, Baker and I started on cleaning the Calipers for paint, and getting the lash adjusters cleaned out and ready to install.

Soon as Rob arrived, ended up getting the last bit of things together, and the engine was back in the car within about an hour (maybe hour and a half). That's including me freaking out for missing one of the engine mounts. lol Had to finagle the transfer case alittle to get the splines to line up, but all went well.

Once the engine was in, I put my DiaQueen and MT90 into their respective places, while Rob worked on the LT axle and got that end finished up. Baker then finished up with the Lash Adjusters (they soaked while we worked on the engine).

So I'd say quite abit got done on the car today: engine in, both axles in and button up, lash adjusters/rocker arms in and ready for cams, and I started to work on the cables and all the fun little stuff while the engine bay is nice and open.

I started to work on getting the thermostat in, but I broke a bolt (break #2), so I decided to call it quits for the night before I chewed my wrenches apart (the door was down, so they couldn't be chucked outside)

Gonna continue working on the cables and whatnot tomorrow. Hopefully I can get everything ready for the intake to go in (at the very least).

And finally the pictures from today. Some of these are from the very start - before anything was done:
41 42 43 44 45 46 47 48 49 50 51


----------Nov 6, 7, 8-------------

Work has gone rather slow the last 3 days. When I get going, a bolt will break, or a hole will thread. I've replaced 3 bolts now due to stripping/breaking.

Tuesday went good. Joe dropped by to help/do the Timing/Cams. Had to fight the belt alittle bit, but all it all it came together rather well. He was happy - ~2 hours for the whole job (including BS time). That made me happy as well.

Wednesday was kind funked. Stripped the hole for the Ilder Pully (WTF does this do?). Ended up getting a slightly longer bold and fabricating it to the hole (hacked it off because it was too long, ground the end to round it properly), and lock-tighted it.

Tonight went OK, I suppose. Vikki was kind enough to work on cleaning my brake calipers so I can (hopefully) paint them tomorrow. I got my power steering and AC pully/pumps in. Found out I spilt power steering fluid all over the floor. Just another cost I guess.

Speaking of which, I am at 5,001.40 spent so far. That's including all parts that I have ordered, and the machine work. I've got a few more odds and ends to get still. This however does not include rad fluid, break in oil, oil, RTV silicone, lock-tight, brake cleaner, and WD-40. I have also spent a few bills on some bolts/washers to replace those broken. Oops. I will of course have a full list (sans prices) once the job is finished.


---------Nov 10, 11------------

Saturday went well. Got my intake in, and my acc belt. Also started to put my exhaust side back together too. Both ex and in needed little more work, but not much since most everything was done on them. Figured I could do the rest on Sunday....

Sunday was hell in a hand basket. I had to tear the intake halfway down again (which wasn't bad, ~20 min), to put some bracket that I forgot about on. Then I was taking a nut off of a stud for a different bracket, dropped the nut, and the damn thing disappeared. I spent nearly an hour trying to find it, to no avail. I swept the floor, took magnets through everything. My only guess is it landed on the K-Bar and is under something that I cannot get to. It can stay there.

After that, I noticed I was missing some covers on my timing belt (little metal covers that cover all of 2" on each side). So I had to put those in. I attempted to do it without tearing everything back down - and that was a mistake. Dropped two bolts down into the timing cover, had to tear my acc belt, my idler pulley, my water pump pulley, auto tensioner, and crank pulley off. Which means I had to drop the engine again - which required me to take the engine mount out again. I left the power steering reservoir bolted in, and that was a mistake. While I was removing one of the pulleys, the engine shifted, and popped the hose off the tank. Then I had power steering fluid all over. Which ate all the undercoating off of my frame horn. Then one of the bolt eyelets for the timing belt cover broke on me. After that, I found that one of the bolts I had in the thermostat wasn't fitting right for that fancy-ass bracket, and I had to replace that....

So for nearly 6 or more hours of work yesterday, I got 3 brackets on. I ended up taking a step backwards too, because my acc belt is off now, auto tensioner, and a good bit of the wiring that I did on Saturday.

I don't think I've been that mad in a long time. So mad, my vision was white and I just saw shapes. IDK why I let it get to me so much, but the main reason I was so fired up, is because every time I tried to do something, I ended up having to take 3-4 steps backwards. Worse, is now I'm set back to about last Thursday.


---------Nov 12---------

Busted some ass today because I was still rather angry from yesterday.

Got the acc belt, timing cover, and all that junk back on. Wired up the rest of my intake (minus the TPS), and got clips for all the plugs (except the TPS, which is getting a paperclip bent for it). Got the vac lines all buttoned up - except for the turbo/boost lines.

So here's my plans for tomorrow:
Center motor mount, radiator & reservoir , downpipe, intercooler & intercooler piping. Fluids (break-in oil, power steering, radiator).

Gonna get the rotors, wheels, and painted calipers on as well to have them ready for the SS lines that are coming. Once she is rolling, I am going to work on getting the rear tires off and the rear calipers so that they can be painted as well.

If I have time, I will be doing my walbro and dash.


------------------Nov 13, 14, 15 ----------------

On the 13/14th, things are kind of a blur. I got the tires on, got the rear calipers off. Got the FMIC & IC piping on, radiator in, reservoir, and fluids in (still gotta fill the reservoir). Got the rear calipers halfway done. Gotta put the front calipers together to put them on the car - was waiting on the SS lines. Was looking to start her up tonight....

But I'm dumb.

I got the AEM gauge in today. Got the SS lines too (a day early!). So I go to work with high hopes. I got the clutch-line in after a good long while (1 hour?) of dicking around with it. I wish I had smaller hands. Then I started to wire the AEM up.... Found out I didn't have any vac lines or connections. So I went to ACO (local hardware), nothing. Went to Pamida (local hick store), nothing. Both Mom/Pop auto stores in town are closed at this time (both close before 7pm). So I had to go to Adrian to Advanced Auto (or AutoZone, depends on whither or not I want to speak Spanish). Picked up a shitton of vac connections and some hose.

Get back to the house, and begin wiring up my vac lines. I thought that one of them needed a T-section, so I started to look at the line diagram.... And found out I didn't need ANY of it!
I did find out that I had a vac line going to my interior already. Which is good. Found out where my gauge is going to go, which is good.

I made little progress tonight. SS Clutch line in, figured out a plan for wiring AEM, and got a bunch of not-needed vac connections.

Gonna go and tackle the AEM tomorrow, that should be rather quick. SS lines will be interesting as I have never done brakes before (or anything else I have done, go fig), and planning on getting the calipers back on too. Though the rear's might have to wait depending on how dry the paint is.

So close.

--------------------Nov 16----------------

Got the rest of the IC piping in today, including intake and battery tray. Got my AEM gauge wired in (minus the interior wiring). start to work on the SS Line (RT Front), and then decided to stop when I decided to try to start the car instead.

Got the battery in, and attempted to start her up. Now we have an issue.

The car is turning over - I can feel the compression in the floorboard. I can hear the starter cranking, I can feel the car cranking, but I am getting absolutly NO fire what-so-ever. It's not even begining to fire.

Anyone have any ideas?

------------Early Nov 17-----

Got the brake lines all in, bled, and connected. Got the calipers on.

Also put the Walbro in - finally. Rob thankfully knew the trick to getting that plate out easily without fighting it forever - which is what I ended up having to do when I first got the car (to check for a Walbro, as I am apparently tone deaf - can't hear other people's Walbro's).

Got no clutch pedal pressure what so ever now. I think it's because the brake res was empty. Rob started to suck fluid through (litterally). Gonna have to figure out that problem - IDK how.

Attempted to start the car before Rob left (and nearly ran him over!). Car still does not fire. We picked up a Code Reader from Adv Auto (thanks for the ride, Rob). I got the code "PO335", which is "Crankshaft Position Sensor A Circuit Malfunction". I checked the plug for said sensor (right behind the valve cover), and it is a good tight fit.

That means I have to tear my timing belt cover back off again. Oh boy. And the acc belt, and all those DAMN PULLIES! Going back out (now) to continue working on it. Hopefully I will have her running tonight. Hopefully.

----------Late Nov 17th-----------

So after above update....

My dad and I went in and ran multiple tests on the wiring of the car. Found that it was getting power to the sensor and that there was a circuit on the sensor as well. Then we ran some other tests, and he determined (through the service manual) that the sensor was either bad, or it wasn't plugged in right down below. Either way, I had to tear back into the nasty-side of the engine.

So I started to do that. I took the battery out, disconnected the LICP, UICP, Intake, and downpipe (in case I needed to tilt the engine). Then I took the wheel off, and began on taking the ACC belt off - which requires some of the most PITA bolts I have ever tried to work on (water pulley). After just shy of two hours of tear down (I was more willing to spend time than chance screwing up the engine), I found my issue (Picture to come later). THe sensor was upside down! I was able to crunch my hand in to turn it around, and turn the engine so that I could get the blade in properly. After that, I connected everything back up (except for the wheel), hopped in the car, and the thing started right up.

So the car runs. Now we have another possible issue...

When I ran it, I ran it for less than 30 seconds (cold as hell, tired, and wanting a warm bed). However, we were able to smell a burnt-rubber-like odor coming from the engine bay. The only things I could think that would do this would be my belts, or something rubbing against a different rubber part. I didn't make time to look into it tonight, but that's on the agenda tomorrow.

--------------Nov 18----------------

Busy day, kind of.

Paul stopped by and hung out for awhile. He found out what was going on with the clutch - the line wasn't tightened down all the way to the outlet pipe. So there was a slow leak there that was causing a loss in pressure. This is why it wouldn't bleed right. Soon as I tightened that up, it bleed and now I have a clutch! (YAY! Progress!)

After that, he gave me the rundown on how my center console was torn appart (yay! no dicking around for an hour!). It was rather easy, though I can see fumbling aound alittle trying to get some of those clips out right.

Once that was out, I began doing my interior modification that I had planned (not going to be pictured till later). Started cutting on that and BS'ing alittle.

Without Paul stopping by, I probably would have fumbled around alot more today. heh.

Later this evening I got the gauge fitted in and wired up. After that, I ran the car for ~5 minutes or so till she got up to temperature. No issues that I noticed. I even moved her out of the pole barn she was resting in - under her own power. She even went into reverse (Oh boy). I am concerned about the smoke though. She's puffing alittle heavy, though I am sure that is because she is running rather rich with the 680cc injectors. Granted, being cold and fresh built too, I'm sure it's going to putter alittle bit. Time will tell.

I hope to have the bodywork back onto the car tomorrow night so I can begin breaking her in Tuesday night. Time for some aimless driving. Just in time for them to raise the gas prices - assholes.

----------------Nov 19, 20---------

Put all the body panels on the 19th. Started to drive it around - and I had a problem with overheating. Didn't get more than 2 miles away from my house, and it was topped off on heat.

And the 20th...
Well. It's been fixored.

Thanks to Rob, my father, in-law, and co-worker for brain storming.

Co-Workers were trying to tell me my Turbo was bad. I felt like I was at AutoZone. My dad and I just started checking the basics - hoses and whatnot. In-Law gave the same type of info. Rob mentioned a thermostat being upsidedown.... Yeah, that was the culprit.

So all that's left:
3" Exhaust Gasket
Gauge Light (heat/fuel section out)
Bleed Brakes (again)
Re-Align lights/bumper
4-Wheel Alignment
New Rubber
Inner Fenders
Break-in

-------Nov 21--------

Finished bleeding the brakes tonight. They work great now.

Put my snorcle back on the air box
Put the inner-fenders in
Re-aligned the lights

Just gotta get on with the brake-in - which will have the first 100 put on it by Friday. Ordered the tires this morning, talked to a couple of different alignment shops. Gotta check out what is happening with the gauge light, and I've gotta get my 3" gaskets in. Those will go in when I change the oil.

Anyone have any particular places they like to take their cars for alignments/mount/balance?


---------------Nov 23, 24--------------------

Since the 21st, I have put nearly 4-500 miles on the car. I've done my first oil change, and plan on doing my second tomorrow. At this point, I basically consider the car done. I have ran into a couple of minor problems though, which I will be taking care of through time. Just going to add it to the "To Do" list:

Last Break-In Oil Change
AEM Tru-Boost tune (only boosting to 10-11psi atm)
3" Exhaust Gasket
Gauge Light (heat/fuel section out)
4-Wheel Alignment
New Rubber

Also got a PPI intake on there. Did alittle R&D with Wayne today. (Was expecting a slightly eaiser install, Wayne. :P ) I'll let him reveal that himself though.


With that, I consider this build to be complete. I'll post the parts list I have in a different thread, since this was more of a "Build" thread, and is rather cluttered now.