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Old 03-11-2013, 12:30 PM   #126
Soarer
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Finally got my issue resolved with running lean under boost. Turned out to be a bad 2" length of fuel line that goes from the fuel pump to the hard pipe out of the the gas tank. No more hard starting or running lean!!! Hopefully getting her tuned tonight.

I'll post a pic of my dash pod soon too.
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Old 03-11-2013, 12:31 PM   #127
Soarer
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Quote:
Originally Posted by Soarer View Post
I'm having an issue with interior lighting. The lights behind the HVAC controls, map lights, boost gauge (samco factory option unit that has the jumper cable to plug right in under the dash) and horn all don't work. I've checked fuses and they're all fine. Need some help diagnosing this one.
I got all this sorted out too. Had a bad connector under the airbag for the horn, bad bulb in the map lights, burnt out HVAC lights which I swapped for a different control unit. All good now!!!
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Old 03-11-2013, 03:19 PM   #128
Patrick Olsen
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Quote:
Originally Posted by Soarer View Post
Finally got my issue resolved with running lean under boost. Turned out to be a bad 2" length of fuel line that goes from the fuel pump to the hard pipe out of the the gas tank. No more hard starting or running lean!!! Hopefully getting her tuned tonight.
That must have taken some hunting to figure out - how did you manage to narrow it down to that? Good to hear that it's fixed!

Quote:
Originally Posted by Soarer View Post
I got all this sorted out too. Had a bad connector under the airbag for the horn, bad bulb in the map lights, burnt out HVAC lights which I swapped for a different control unit. All good now!!!
I haven't checked into this thread in a while, but your post about all the lights being out was the first one on the last page that came up for me. The little HVAC bulbs burning out is a very common issue; somewhere on here or many on scoobymods.com or sl-i.net there's a writeup of how to replace them. The bulbs in your "new" unit will probably do the same thing eventually, and they're not too terribly difficult to replace.
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Old 03-11-2013, 03:28 PM   #129
Donzo
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Great news!!
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Old 03-11-2013, 04:16 PM   #130
Soarer
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[quote=Patrick Olsen;39332647]That must have taken some hunting to figure out - how did you manage to narrow it down to that?

I tested the fuel pressure and it was dropping off quickly after priming (when the motor was not running but I would turn the key to on). So, I figured that the pressure was leaking somewhere between the FPR and the fuel pump. Since there was no leaking fuel anywhere I could see or smell, figured it had to be in the tank. Turned out to be this
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Old 03-12-2013, 10:56 AM   #131
Soarer
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Mikey tuned my car last night. She's finally running 95% like she should. The only issues we ran into were a slight hiccup when I stomp on it and it didn't take a lot of timing.

I'm going to run some high quality gas through it and double check that my timing gears are all lined up correctly to see if we can sort out those two things.

Right now she's running 20.5 psi and pulling pretty hard. Looking forward to putting some real miles on her.
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Old 03-13-2013, 06:19 AM   #132
celosteelo
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Quote:
Originally Posted by Soarer View Post
Mikey tuned my car last night. She's finally running 95% like she should. The only issues we ran into were a slight hiccup when I stomp on it and it didn't take a lot of timing.

I'm going to run some high quality gas through it and double check that my timing gears are all lined up correctly to see if we can sort out those two things.

Right now she's running 20.5 psi and pulling pretty hard. Looking forward to putting some real miles on her.


Congrats man! Sounds awesome! Can't wait to see and take a ride in it!
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Old 03-13-2013, 11:38 PM   #133
tirkish
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So pumped! Awesome job and awesome dedication sir.
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Old 04-03-2013, 10:49 AM   #134
Soarer
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JDM version 7 six speed just arrived last night. Already got my trans half out. Should have this new one in very soon. Psyched!!!


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Old 04-03-2013, 12:47 PM   #135
Donzo
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Siiiiick!!
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Old 04-03-2013, 01:27 PM   #136
06wrxlbart
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A local tuner.

Nice project good luck.
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Old 04-06-2013, 06:17 AM   #137
Soarer
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v7 6sp installed and shifting like buttah!

Also, previously I had very, very stiff clutch pedal. I had chalked it up to the heavy duty Exedy pressure plate. I had a 13/16" slave cylinder and an 11/16" master cylinder with a braided line in between. When I got the v7 trans, I noticed that the slave had another piece connected to it. I think this is a controlled release valve basically designed so that the clutch can't be engage too fast. I decided to use this slave instead of my old one. Both were 13/16" but the new one feels sooooooooooooo much better. The pedal is much lighter. It's how it should be now. It's just heavier than stock but not too heavy as it was with the old slave. I'm very pleased!! Also sold my old 6sp to offset the cost of this one! Win/win.

I've just gotta get my hesitation issue sorted out and the car will be 95% done!
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Old 04-06-2013, 06:27 AM   #138
Soarer
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I thought that I should include some linked threads that I created in regard to issues I've run into along the way in my build. Here they are:

Tuning issue:
http://forums.nasioc.com/forums/show....php?t=2479650

A hybrid ventilated valve cover setup I made but never used because I went to B25 heads:
http://forums.nasioc.com/forums/show....php?t=2454826

R160 MLSD & Axle issue:
http://forums.nasioc.com/forums/show....php?t=2405757

Wiring issue:
http://forums.nasioc.com/forums/show....php?t=2462014

Running Lean under boost:
http://forums.nasioc.com/forums/show....php?t=2464935

Adding AVCS
http://forums.nasioc.com/forums/show....php?t=2435581
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Old 04-06-2013, 09:26 AM   #139
tirkish
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You, sir...are a nerd of the best kind. Bueno.
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Old 04-22-2013, 03:16 PM   #140
Soarer
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I think I've isolated what is causing my hesitation problem. I did a boost leak test yesterday to find that my injectors are leaking at the seals where they go into the intake manifold. I'm running a v8 long runner JDM manifold with adapter plates to use USDM fuel rails. It seems that the adapter plate is about 1mm too thick which is spacing the injectors a little too far away and not pinching them into the manifold tight enough. 3 out of 4 injectors were leaking under the boost leak test at 7psi. I'm thinking that I'll just swap back to a USDM manifold and do a TGV delete. At least that way I'm confident I can get the injectors to seal.
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Old 04-22-2013, 03:20 PM   #141
celosteelo
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Sounds legit.
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Old 04-29-2013, 04:45 PM   #142
Soarer
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Got the TGV delete done this weekend and painted the USDM manifold black. Just need to clean and paint the TGVs, put the manifold back together and install it. Hoping to have all that done this week.
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Old 05-01-2013, 04:25 PM   #143
Soarer
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Got the TGVs painted and ported. Gonna put the manifold back together tonight and installed by tomorrow.
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Old 08-23-2013, 12:06 PM   #144
Soarer
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Finally got the intake manifold installed and did a boost leak test. NO LEAKS!! Had Mike Botti tune the car on Tuesday and it is finally running the way it should. I'm very, very happy!

Next jobs to do: adjust valve clearance, charge AC, install JDM fogs, figure out where some front suspension noise is coming from, tint windows
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Old 08-27-2013, 08:17 PM   #145
Soarer
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Spent about 5 hours last night sorting out a few issues. My fuel gauge was reading very high. After I would fill up, the gauge would read way past F and I'd run out of gas when it still showed about a quarter tank. I had a spare gauge cluster so I swapped that in. Took about an hour to get all the back lights to work. Then during the test drive, the speedo didn't work and I got a CEL for speed sensor. I pulled the cluster out and took it apart and put the speedo from my old cluster in the new one. Test drive.... temp gauge now reading way high. Pulled it out again and swapped over temp gauges. Bingo!!! She's all working now. And I'm happy to have an accurate odometer in the car reading 186k. It's like a badge of honor.

Then I hard wired in my Passport 9500ix.

Then, I put an ECU flash button in so that I don't have to connect those stupid green connectors every time I flash an new map on the ECU. Now I just push a button!

Next projects: valve adjustment, steering rack realignment, ball joints, window tints, charge AC., detail exterior, paint skirts.
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Old 08-28-2013, 09:49 AM   #146
tirkish
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Still waiting for a ride in this beast!
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Old 08-28-2013, 04:27 PM   #147
celosteelo
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Quote:
Originally Posted by tirkish View Post
Still waiting for a ride on this beast!
I want a ride... but in the car though.
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Old 08-28-2013, 04:30 PM   #148
tirkish
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I want a ride... but in the car though.
Sissy
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Old 11-13-2013, 01:37 AM   #149
swagger
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you are killing it! i have been ripping my hair out figuring how to fit a 04 wrx 5 speed MT into a AT 92 legacy wagon. the cross members are so different and I'm just stumped on what to do. if you have any input or could post some photos of how you made it work that would be much appreciated. Your swap has really inspired me to get my project running, thanks.
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Old 11-13-2013, 01:14 PM   #150
blakeM.U.R.T
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DUDE VERY NICE! your trouble shooting skills are prime! this has me itching to do the swap in my 96 impreza wagon. just dont have the funds.. story of my life
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