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well no pictures this time.. just an update..
today I got my turbo built... I took it outside got the exhaust manifold bolted with a new Mazda oem gasket.. put the turbo on and I only had the 1 main oil drain line so I figured I could just cut the line and make it work with some heavy duty hose... After messing around for over an hour all I did was ruin a god piece... so I just had to buy both pieces from a member here so I can get it bolted up.. I then went to put the coolant line on to the intake and noticed that got damaged in shipping so I had to buy both of them too.. just a setback I should still have everything here and ready to have on for this weekend when I put the engine in.. I will update u guys even more. |
Today I came home to some good news..
ITS HEEERRRE!!! Spec Stage 3 6 puk n/a clutch kit http://img.photobucket.com/albums/v8...cclutchkit.jpg http://img.photobucket.com/albums/v8...cstage3kit.jpg http://img.photobucket.com/albums/v8...ssureplate.jpg http://img.photobucket.com/albums/v8...e/spec6puk.jpg http://img.photobucket.com/albums/v8...ecbearings.jpg So now I just need to get it all ready to bolt on. |
soooooo close to being done. good choice of clutch. i had one on my old FD and i loved it. now you can actually get the engine in and going!
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This weekend the engine will be in
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Well the dealer did not come through they got me the wrong bolts and wont allow me to return them even though they looked them up..
im out 26.00 on 6 bolts and a spacer none of which I can use or need... GRRRRR! why is it I cant find grade 8 metric bolts anywhere?? |
Well I found some bolts tonight.. got home put the water pump, water pump housing on turned the engine around got the flywheel on and realized the bolts are to long.. so I used an extra washer to shim them out a touch now they seem fine EXCEPT the head sticks out to far now and the clutch disc cant sit the way it should
basically the bolts are to damn long.. back to the drawing board again!!! |
They had the right size botls.. tonight I will have the flywheel on, clutch on, water pump will be tight and bolted on, thermostat will be in and the neck will be on.
the turbo will be bolted on and the lines run. I will be spraying the engine bay out with brake clean to get things cleaned up.. I will install the release bearing and then tomorrow after work me and my buddy are gonna drop this baby in then I can get the upper intake all cleaned up and painted get the electrical done get the fuel pump installed get the ecu in and next week I order up my intercooler kit I plan to have this car running by the end of the month. |
that clutch wont be bad its a sprung hub.. I have drivin many 6 puk clutches before..
anywho on to the pics.. flywheel on: http://img.photobucket.com/albums/v8...e/DSCF3592.jpg clutch disc on: http://img.photobucket.com/albums/v8...e/DSCF3593.jpg pressure plate on: http://img.photobucket.com/albums/v8...e/DSCF3595.jpg Water pump pulley is on.. its smiling: http://img.photobucket.com/albums/v8...e/DSCF3597.jpg http://img.photobucket.com/albums/v8...e/DSCF3599.jpg more pics http://img.photobucket.com/albums/v8...e/DSCF3604.jpg http://img.photobucket.com/albums/v8...e/DSCF3606.jpg http://img.photobucket.com/albums/v8...e/DSCF3607.jpg I am currently fighting with the turbo it needs to come back off and everything spun the right direction then put back on.. I was trying to angle the compressor housing but if I do that the wastegate actuator wont bolt on :( Tomorrow the engine goes in.. I will prolly drop it in without the turbo so I can redue that after I get it right |
The engine is in... I have to give a big thanks to both my friends Aaron and Mike... without them I would have never been able to do it...
I got the turbo off (so I can fig the problem with its location), I swapped in new engine mounts and then we got the engine on the hoist.. It was a pains since we left the tranny in... we started to get it lined up and I asked to pull it out so we can get it strait and I noticed I forgot the release bearing lol.. I got that on then we tried someone more with no luck.. I left for 5 minutes to take my nephew to work leaving them there.. I came back and they had the engine being bolted together.. I helped finish that up got the starter on and no I just need to finish the rest... anywho onto pics.. http://img.photobucket.com/albums/v8...e/DSCF3617.jpg http://img.photobucket.com/albums/v8...e/DSCF3616.jpg http://img.photobucket.com/albums/v8...e/DSCF3618.jpg http://img.photobucket.com/albums/v8...e/DSCF3619.jpg http://img.photobucket.com/albums/v8...e/DSCF3622.jpg http://img.photobucket.com/albums/v8...e/DSCF3623.jpg More to come |
ok its a bit cold today so I did not spend much time (as of now out there) I mannaged to do the following
connect the front oil cooler line connect the wire to the oil pressure sensor connect the wire to the oil pressure sender box put in the spark plugs put on the new slave cylinder and SS braided line and bleed put the inspection cover on over the flywheel I will need: new banjo bolt for the rear oil cooler line I still need to reclock the turbo corectly, clean and paint the uim, get my injectors back, change the fuel filter, get new fuel hose, get that all mounted and then get the intercooler mounted and plumbed (once it arrives) then I can start on the inside with installing the ecu, fuel pump, get the battery charged and give it a try! |
Here is a few pics.
I got the oil filter pedestal on got the turbo clocked and all bolted on got the outer coolant line hooked up to the lim what a pain to bolt the turbo to the manifold with the manifold in the car on to pics http://img.photobucket.com/albums/v8...e/DSCF3625.jpg http://img.photobucket.com/albums/v8...e/DSCF3626.jpg http://img.photobucket.com/albums/v8...e/DSCF3627.jpg http://img.photobucket.com/albums/v8...e/DSCF3628.jpg |
last night I went out and bleed the slave cylinder completely through with some elf dot 4. tonight I am going to go pickup an end for the turbo feed to the front iron. The injectors should be here today and if so I will install those and then get the upper intake cleaned, ports blocked, outer lower plates removed, and painted
this weekend if everything goes well I plan to have the intercooler being installed, the engine done, the ecu swapped in, and the only thing left will be the fuel pump... I hope this all works out and I get it done in the next week or so. Start up is getting real close. |
Here are some pics from tonight
Got the injectors in and the fuel rails on.. I have 2 of the 3 fuel lines on.. and the wire harness ran and lots of plugs hooked up.. http://img.photobucket.com/albums/v8...eandwiring.jpg http://img.photobucket.com/albums/v8...ecfuelrail.jpg http://img.photobucket.com/albums/v8...ne/theugly.jpg Tomorrow I need to put a new end on the wire for my coolant temp sensor (on back of rear iron) tonight I plan to clean up the uim and if I have paint down stairs I will paint it up.. Hopefully I can get a new fuel filter come thursday.. install that and the fuel line to it and then put the uim on... |
Nothing to eventful today...
I got my rear oil cooler line on, got the upper intake painted (got something special for you) when I get pics of that. sprayed the engine bay down with brake clean... tomorrow I will clean it with engine degreaser then more brake clean and hopefully it will be decent.. I got to order up a few items but I should have the upper plenum on by Saturday (wont get much time tomorrow or friday to do any work on it) Plan to get the intercooler on or close to on this weekend.. A bit closer I am ! |
Quick question.
Why keep the S4 turbo? All that goodness, and then that! |
Is it really that much different from the S5? Basically, S5 has a slightly larger turbine and no twin scroll, right?
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because I have the S4 turbo, and manifold and because I am running the stock ecu for now sine I will be on the stock n/a drivetrain so I want to get the engine broken in, enjoy it this year then swap the drivetrain then upgrade the turbo and manifold...
Just the way I work.. first rotary build.. since I did it all I am still scared to turn the key.. no need to make it even harder on me for the first one.. |
great logic... why make things more complicated then they already are (na to turbo swap)
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I'll have to finish this read tonight, but wow. Great build thread for sure.
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Paint the whole thing
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That intercooler is going to create alot of lag with the stock turbo. I am running a ceramic coated S5 turbo with ported turbine inlet and a monster wastegate port. I have that same intercooler, but there is no need for it with any 'stock sized' turbo, so it sits in the garage.
Just an FYI. |
Yeah I know it is overkill when I bought it I never imagined it would be that big...
I plan to run it but I also plan to upgrade the turbo later down the road (in the near future) and yes I will be painting the entire intake tonight I am not fond of it as did it |
I painted the uim all gunmetal...
I also mounted the intercooler today http://img.photobucket.com/albums/v8...I/IMG00019.jpg Sorry for the big pic. |
Well here is what I have got accomplished today
http://img.photobucket.com/albums/v8...I/IMG00020.jpg I have the holes cut so the pipes are going into the engine bay I just need to get things snugged up and clamped down and a couple pipes cut and it will be on... first I need a higgi/greddy elbow another thing I forgot last minute taken with cell phone sorry for the big pic |
ok here are some I got from late tonight... I got the holes cut, the pipes run into the engine bay now I just need a couple couplers, and the higgi/greddy elbow
http://img.photobucket.com/albums/v8...e/DSCF3708.jpg http://img.photobucket.com/albums/v8...e/DSCF3698.jpg http://img.photobucket.com/albums/v8...e/DSCF3704.jpg http://img.photobucket.com/albums/v8...e/DSCF3700.jpg http://img.photobucket.com/albums/v8...e/DSCF3703.jpg http://img.photobucket.com/albums/v8...e/DSCF3701.jpg http://img.photobucket.com/albums/v8...e/DSCF3702.jpg Yes the car is on an angle.. OK what do u think? |
Ok no pictures today (atleast not now)
I have done the following turbo ECU installed Walbro installed TPS wires lengthened I need 2 couplers 1 banjo bolt and the higgi/greddy elbow and I can get the car ready to start |
I am runnin gthe same intercooler o my fb setup and boost does not hit until 4 grand. Makes me wonder how fast it would hit with no inter-cooler!
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full boost at 4k? or are u in hg until 4k?
what size turbo are u using? im not to worried I will be breaking the engine in for a while anyways.. after I am broken in I may upgrade turbos. right now im just waiting for a few parts |
full boost buy 4k at 0 buy 3,500 then its like someone turned on a switch and blam off i go. It could be part of it being a 12a thats driving the turbo but other 12a guys with s4 turbo hit around 3k so i think its the cooler. I have the same one its massive about the size of my radiator almost.
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well thats nice then.. 0 boost at 3500 and full boost at 4 k right at the power band
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So today I got the oil injectors on the rotor housings blocked today, I ordered up my banjo bolt for the pd removal and a coupler for the turbo to intercooler pipe. I should have my throttle cable tomorrow and my gasket for my oil feed line
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Got the new accelerator cable on today, the banjo bolt and coupler will be here tomorrow so I should be able to get the fuel lines on, the upper plenum on, the turbo side of the intercooler all done.
I bought a tb elbow today it should be here by friday along with my new modded tb so I can get them on and the intercooler pipes for that side by friday.. Then add oil, coolant, and get the last few things on... I hope to turn the key by Saturday or Sunday |
The official startup will be roughly 3:30-4:30pm on Saturday
My throttle body showed up today my banjo bolt and 1 coupler is due in today my downpipe and tb elbow should be here tomorrow or friday latest I work till 3pm on saturday.. I will be going home. getting the camera out and starting the car.. I am SO SCARED!!! |
Ok so tonight was a good night.. my banjo bolt showed up so I was able to get my fuel rail on. The throttle body showed up so I was able to get that on and the upper intake on. The coupler showed up for my turbo to IC piping so I ws able to get the passenger side plumbed...
So all I have left is to: put my throttle body elbow on when it shows up put my turbo oil feed line on when it shows up put my turbo coolant line to intake on when it shows up Put my AFM on put radiator in and add coolant put the down pipe on when it shows up Put on the new ngk wires put the alternator on put 2 new belts on I did get the engine filled with 4 litres of Elf 10w50 on to pics http://img.photobucket.com/albums/v8...e/DSCF3716.jpg http://img.photobucket.com/albums/v8...e/DSCF3715.jpg http://img.photobucket.com/albums/v8...e/DSCF3714.jpg http://img.photobucket.com/albums/v8...e/DSCF3713.jpg http://img.photobucket.com/albums/v8...e/DSCF3712.jpg http://img.photobucket.com/albums/v8...e/DSCF3710.jpg http://img.photobucket.com/albums/v8...e/DSCF3709.jpg So I am about positive that I will turn the key on Saturday |
Ok so tonight I have done the following...
put the tb elbow on and the coupler on got the intercooler piping on the drivers side on and the bov mounted got the radiator in thermostat in coolant added a couple hoses on got the oil feed one got the coolant feed on got the coolant return on I need the following yet put the afm on get a new bolt for the t-stat housing get a radiator cap get a vac hose for brake booster to uim get some plastic put back on here are pics of what I have done tonight http://img.photobucket.com/albums/v8...e/DSCF3722.jpg http://img.photobucket.com/albums/v8...e/DSCF3721.jpg http://img.photobucket.com/albums/v8...e/DSCF3720.jpg http://img.photobucket.com/albums/v8...e/DSCF3719.jpg http://img.photobucket.com/albums/v8...e/DSCF3718.jpg http://img.photobucket.com/albums/v8...e/DSCF3717.jpg |
Ok well I got the last few things on.. checked my fluids etc and of course nothing can go off perfectly..
We pulled the fuel pump fuse cranked the engine to build oil pressure and 3 seconds into it the upper fuel rail sprung a leak... found out the banjo bolt was loose.. so we realised there was a leak and that we had the wrong fuse pulled... so we cleaned the engine off with water and tried again this time on purpose with the pump on to see if any other leaks happen What do u know crank a few seconds and bam the lower rail leaks.. I tighten that bolt and pull both the fuses and crank till oil pressure comes up.. once that works we put the fuses in and crank 2 it took like 2 seconds and the car started and ran just fine... we had it die because the throttle adjustment was not set right... we turn the adjuster screw in so it will idle on its own and it fires right back up... I let it run for about 45 minutes or so and it just smoked and smoked and smoked... it still smokes if I start it.. Not sure how long it will smoke for but I know with the crisco, gear lube and engine oil used during the engine build process I figured it would smoke for a while.. after a while I turned the ca and found the low oil level light was on.. so I check the oil and it is fine... a little later it hit me.. I may have grabbed the n/a dipstick instead of the turbo dipstick... sure did so after adding another 2 liters it is just under full The next thing I noticed was I had lots of bubbling in the cooling system so after that cooled down I pulled the bleed valve on the side of the radiator neck (again) and refilled the cooling system.. this time I am confident that it could be all done up.. now the biggest problem.. the batter wont hold a charge and it really is to big now with the ic pipes run .. tomorrow I will get another battery, get it started back up and let it run for a while longer.. hopefully the smoke will go away... Anyways I got 2 short videos.. NO SOUND SORRY.. but u can see the horrific amount of smoke... as for the smoke shooting from the turbo in the engine bay well the downpipe was only held on by one nut, and I did not have a gasket on it because i only had one nut holding it on.. so one that is all tightned down I should be all set there.. http://img.photobucket.com/albums/v8...h_DSCF3723.jpg http://img.photobucket.com/albums/v8...h_DSCF3724.jpg |
Congrats!! :biggthumpup: looks like she's running strong.
:driving: :driving: :driving: :party: |
is that amount of smoke or that long normal.
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Yep
http://www.rotaryresurrection.com/2n...p_breakin.html 6) Be prepared for smoke…there is assembly lube in the engine, which will be burned out in the form of smoke. Expect this to get into your exhaust and smoke can remain for up to 8 hours afterwards until it is all burned out slowly. |
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