TobyCat's winter buildup

TobyCat

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#86
strikes me that I should measure the deck height. How would I do that? I used a caliper inside each piston to measure the stroke depth and it looks like I'm down on average 0.3mm off of spec. I have a stock sized Cometic head gasket (1.37mm). I haven't measured the head yet but that won't be zero.

Looks like I should go for a 2mm gasket. The HKS ones are serious $$, Titan/Cometic seem to be OK and well received.

Unrelated note - Looking for some adjustable cam gears.
 

TobyCat

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#87
Well, there's nothing like a deadline to get the car put back together! I put in about 2 weeks of evenings getting this thing back together :)

Since I lapped the deck a bunch, I measured the deck amount removed + head and ended up getting an HKS 2MM stopper gasket.


Gasket On:


And bolted down!



It then sat like that for ... a while. I picked up some Titan adjustable cam gears:



Then got the turbo and lower intake manifold back on and let it sit for well over a year :/
 
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TobyCat

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#88
Then in early Feb, picked up where we left off

Put the intercooler and the Mashimoto radiator on:


There was tons more to do than I remembered. The instructions on assembly where it says "do reverse of disassembly" is only useful if you remember how you took it apart ;) Thankfully we took a *ton* of photos.

Fans on:






Upper intake manifold + vacuum lines + wiring harness took a bunch of time to diagnose wtf was going on since it was all in pieces on the bench. I'm so glad that I labelled all the bolts into bags as things came off. Made assembly slightly less painful


Coming together! Upper intake done, lower rad hoses and intercooler piping (total bitch!), coils+wires etc.. The CPS cover just disintegrated so had to order a new one


That's where I left it after a few weeknights.
 
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TobyCat

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#89
Now the homestretch!

This was all that's left to do:


to be put onto here:


And this is all the bits and bobs back on:


At this point, I filled up coolant, oil, PS fluid. Only had one leak on lower rad hose which was a simple fix!

Put the battery in and tried to fire it up - it tried to catch but wouldn't really. Some diagnosis later ...


Found that the lower vacuum wasn't connected. I put 10L of 94octane in the tank and fired it up. This time it ran!


Dropped the oil, cleaned up all my tools, took it for a few laps around the block and it drove!
 
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TobyCat

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#90
Got some temp insurance then went out for a drive back to my apartment :)


Things left to do:
- the idle refuses to work. I've checked vacuum lines, it runs when I unplug the ICV but surges between 1k-1.5k rpm which is annoying. Could be the TPS
- wire up the electric fans. Turns out the fan Mashimoto "kit" comes with nothing :/ Gotta order the temp sensor and wiring kit seperately
- get timing done. Right now the CPS is on 0
- drop oil + coolant another time
- wash it ;)
 

plaaya69

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#91
Glad to hear you got it driving. I don't think the picture links are working in the above posts.
 
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TobyCat

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#95
I haven't picked up a kit yet but will get the temp prob mashimoto kit to wire up the fans. I was able to drive home without trouble since it was below freezing and I had the heater on full :)
 

NashMan

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#96
I haven't picked up a kit yet but will get the temp prob mashimoto kit to wire up the fans. I was able to drive home without trouble since it was below freezing and I had the heater on full :)
You can uses a Honda fan switch found in the d16 pretty sure the b series is the same then thread it in the oem thermostat houseing
 

TobyCat

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#97
@NashMan is there a good guide out there somewhere on how to wire up electric fans? I no longer have the twin aux fans installed so there is a plug sitting there right near the battery I could reuse.
 

TobyCat

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#98
Thinking I should wire up the driver's side electric fan to the same circuit as the A/C condenser fan switch, then the passenger fan which replaces the stock one to a thermal switch.
 

TobyCat

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#99
OK, still can't figure out the idle problem, but getting closer. I picked up a vacuum tester and tried a few spots around the engine.

Cold and at idle (ish ;))

FPR - 15mmHg
Back of Intake nipple - 15mmHg
Throttle body right side - 0
Throttle body left side (which goes to BOV) - 0

From what I've gathered on the internwebs, It should be around ~20mmHg at idle.

Potential problematic spots:
valve cover breathers - I replaced those with ugly generic coolant hoses
accordion hose to passenger metal tubing - I have an aftermarket metal turbo intake pipe and at the cross-pipe doesn't quite fit right, but it's new
cold start injector - I didn't have the gasket so use make-a-gasket to get the car running. Could be leaking
VSVs - I hear suction sound beneath the intake manifold at idle, but not sure if that's normal on cold start.

I checked all other vacuum lines and they're all connected fine and look OK.

Did some search - looks like on startup there should be no vacuum on startup to FRP via the vsv. Based on my measurements that's wrong. Looks like my FPR one is defective.
 
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TobyCat

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@shipkiller yeah I"ve tried to set the timing, but it's pretty tough with such a rough idle. Got it as close to 10 as possible. I'll pull out the CPS again and make sure I'm not off a tooth.