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Old 05-07-2012, 12:20 PM   #51
Zaider
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Spent some time this weekend installing the new turbo. Some bolts decided to fight me which made it a lot longer of a process than it needed to be. Further, I found a couple pieces that Im missing (bolts and some new rubber hose) so I'll pick those up and give'r again tomorrow.

First, during the removal of the header heatshield, one of the welded-on nuts on top of the heat shield came loose and it took forever to get a wrench on there and hold it so I could remove the bolt so that I could even get to the nuts holding the header to the block. That was literally about 2 hours of back and forth between multiple wrenches and I even started to dremel apart the headshield cause I was so frustrated at it. Finally got it off though.

Next, the two bolts going from the downpipe to the mid-pipe were completely rusted and even with liberal amounts of Release All, it was a bitch to get them off so I could remove the downpipe. Time to find some stainless steel bolts because I never want to go through that again.

The good news:

Currently, the new maddad header and uppipe are on and torqued down. The heat wrap took a bit of a beating while it was going on as it was going by the subframe so we'll see how long that lasts. I could always cut it off if it starts to fray and just rely on the thermal coating.

The new turbo is also on, with the inlet all on (I knew that would take some time) so that's nice that its done. The oil and coolant lines are all attached as well. The Dom 1.5XTR has wider fittings for the lines to the EBCS and back to the wastegate so I need to get some new rubber lines and run those. The stupid fitting on the wastegate is placed on the bottom of it so its a really frustrating place to get a line on. Also, one of the nuts that attaches the turbo to the uppipe wont fit on. All of the nuts that I have are flanged and the flange wont allow the bolt to get onto the stud. Even getting a single non-flanged nut on, there's no room so I need to go grab a small 14mm wrench. Pretty sure this is a common problem when installing turbos though.

Also, while I remember, the banjo bolt in the oil feed line on the EJ207 does have that stupid oil filter. I removed that while I had everything apart. The screen size on that is so small, I can't believe it wasn't blocked already but it looked fine.

The VF30 I removed has zero shaft play, and the blades all look to be in really good condition.

The downpipe is mocked up and a couple of the bolts are on to attach it to the turbo. I've got to grab a few more bolts to finish up attaching the downpipe and im going to get new bolts to attach the downpipe to the mid-pipe because when I finally got those off, I threw them into the back alley in a display of dominance. Getting the DP back on means that I can do the rest by myself so the couple friends that were helping/making fun of me could go home.

I've still got to install the front O2 sensor and the Defi EGT probe into the header. Spark plugs and fuel injectors still need to be done as well. After that, its just putting the intake and TMIC back on and putting the battery back in and then I can start'er up.
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Old 05-07-2012, 08:07 PM   #52
alcoolaid
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Nice turbo. Dom 1.5 is the shiet!
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Old 05-08-2012, 07:53 PM   #53
Zaider
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Quote:
Originally Posted by alcoolaid View Post
Nice turbo. Dom 1.5 is the shiet!
Thanks. The suspense of what Ill actually put down is killing me.

I sorted out some small details today... basically getting it to the point that I can drive it down to my local shop, Vex Performance, and get them to do the fuel injectors and test it for boost/exhaust leaks.

I was going to get them to do the spark plugs as well and go one step colder, but im going to try to get away with what i've got right now. If my tuner says I need to go colder, then ill change em over.

Technically I guess I could do the fuel injectors but the GBOD looks intimidating and im at the point that I just want it done and back on the road.

My tuning appointment is on Tuesday
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Old 05-10-2012, 07:26 PM   #54
Zaider
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Results of me messing up my turbo install.

Step 1

Untitled by zcherniawsky, on Flickr

Step 2

Untitled by zcherniawsky, on Flickr

Step 3

Untitled by zcherniawsky, on Flickr

And its off to my trusted shop to have them fix my mistake.
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Old 05-10-2012, 11:42 PM   #55
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What happened???
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Old 05-11-2012, 10:19 AM   #56
Zaider
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Finished the install. Primed the oil. Turned the motor over and oil started leaking onto the garage floor. I think its from the turbo oil feed line where it goes into the motor. I dont have the energy or patience to tear everything apart and fix it.
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Old 05-11-2012, 11:26 AM   #57
rs420
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I hope its a easy fix! I cant wait to see the numbers she puts down
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Old 05-11-2012, 03:00 PM   #58
Zaider
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Originally Posted by rs420 View Post
I hope its a easy fix! I cant wait to see the numbers she puts down
You and me both... on both counts.

My tuning appt was tuesday but with this latest setback, I doubt Ill make that.

Probably have to wait until the week after.
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Old 05-25-2012, 09:27 AM   #59
Zaider
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Car is misfiring (no CEL) and has a low idle when warm (~700rpm). Going to go see my tuner today to see if he can figure out whats wrong. Im thinking one of the DW750 injectors I installed is faulty.

In other news, I got this last night.


Carlabs X-Brace by zcherniawsky, on Flickr

I need to track down the two bolts that attach the X to the strut tower braces and then it'll get installed. I've got the 12L Spec C tank in the trunk but I ordered a set of spacers from Oswald Performance so I can run both. Apparently the install is a PITA.... yay. :sarcasm:
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Old 05-25-2012, 02:46 PM   #60
rs420
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Quote:
Originally Posted by Zaider View Post
Car is misfiring (no CEL) and has a low idle when warm (~700rpm). Going to go see my tuner today to see if he can figure out whats wrong. Im thinking one of the DW750 injectors I installed is faulty.
So how has the car been running since it was fixed/tuned?
is it something that has changed? or been misfiring since the tune?
Quote:
Originally Posted by Zaider View Post
In other news, I got this last night.
I need to track down the two bolts that attach the X to the strut tower braces and then it'll get installed. I've got the 12L Spec C tank in the trunk but I ordered a set of spacers from Oswald Performance so I can run both. Apparently the install is a PITA.... yay. :sarcasm:
That looks nice, I really want alot of the parts from your car
anytime you wanna sell something, let me know
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Old 05-25-2012, 03:56 PM   #61
Zaider
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Originally Posted by rs420 View Post
So how has the car been running since it was fixed/tuned?
is it something that has changed? or been misfiring since the tune?
Thats the thing, it hasn't been tuned. My tuner stopped by and gave it a safe tune when I picked it up from the shop but no full tune yet. He doesn't think its a tune related issue. Maybe a bad injector?

Quote:
Originally Posted by rs420 View Post
That looks nice, I really want alot of the parts from your car
anytime you wanna sell something, let me know
lol. I seem to keep collecting them. Ill install the X-Brace this weekend. I thought about powdercoating everything Cherry Blossom Red but I think I'd rather just install it.

I've recently made the mistake of looking at expensive wheels... sigh... not sure how far I want to push fitment... but an 18x10 set of CCW LM20's would be pretty damn nice. Gotta get the car running properly first.
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Old 05-25-2012, 08:14 PM   #62
Zaider
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My tuner, Airboy, was concerned because everywhere in the engine bay that I measured, the voltage was steady, however the ECU was seeing varying voltage. He pulled the ECU out and started testing wires. Sure enough, all the ECU grounds had an extremely high resistance (4+ohms). Something was wrong with the grounds. I called Brian at iWire who did my wiring merge and he said that all the ECU grounds terminate at the Intake Manifold.

Fast forward a few minutes to this bolt:


Bolt by zcherniawsky, on Flickr

Somewhere along the line, this bolt was undone and not tightened back up which meant that the ECU wasn't grounded properly. Sunny cleaned up the grounds and the grounding point and tightened the bolt. Started the car... ECU is seeing steady voltage. Better than that, the Idle was normal. Better than that, no misfires when we revved the motor up.

Huzzuh!

The car is now ready to be tuned whenever Airboy has an opening. We did a couple of pulls, turbo should make full boost by around 4200rpm-ish (yay Altitude!). Once you get up there, it feels pretty damn powerful... but thats compared to me limping the car around with misfires and an unhappy ECU.

Huge thanks to Airboy... amazing work as always.
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Old 05-26-2012, 06:26 PM   #63
Zaider
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I installed my Carlabs X-Brace today. The install wasn't as bad as I'd heard. Took me about 2 hours start to finish and I was working by myself. Sorry about the iPhone pics.... my DSLR battery was charging.


Untitled by zcherniawsky, on Flickr


Untitled by zcherniawsky, on Flickr
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Old 05-26-2012, 07:15 PM   #64
rs420
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sweet man, that looks like it shouldnt have been that tough of an install

i love the look when you drop the pass through and have your brace showing

what you doing with your old vf30?
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Old 05-26-2012, 09:42 PM   #65
Zaider
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Originally Posted by rs420 View Post
sweet man, that looks like it shouldnt have been that tough of an install

i love the look when you drop the pass through and have your brace showing

what you doing with your old vf30?
The only difficult part is getting all the bolt holes to line up properly under the rear seat. It takes some playing with the adjuster to get it setup, then its just putting everything back together.

The VF30 and injectors sold before I could post them for sale
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Old 06-19-2012, 10:25 AM   #66
Zaider
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Well. Figured I'd post a short update. We encountered some issues tuning the car at peak boost. It seems to be cutting out (misfiring slightly) at ~5000rpm. While I sort out the issues, I'm running the car at 18psi max. Hoping to be able to push it up to 21-22psi but anything over 18psi causes the misfire (no CEL, just a stutter).

In the meantime, here is a comparison between my old VF30 tune (blue lines) and the new tune


Untitled by zcherniawsky, on Flickr

As you can see, I've lost about 500rpm to lag but gained a fair bit of top-end. Overall, the way I would describe it is that the car is currently faster than it was, but maybe not as quick (if that makes sense). I think that'll get fixed when we are able to turn the boost up again.

Right now, that list of possibilities is:
1) Wrong spark plugs... unlikely. The plugs in there when the problem started were too hot (NGK BRK6EIX). First thing we did was change them out for Denso IK24's (equivalent to BRK8EIX). The problem persisted. I find it hard to believe that switching to a BRK7EIX would magically fix the problem. Im still going to pull one and take a look for any buildup of carbon that would illustrate that the plug isn't heating up to its correct temp to clean itself.
2) Coilpacks going bad. I need to borrow a set of working coilpacks and see if this helps anything. The theory is that since I am asking so much more from them with the higher air flow, they're starting to crap out.
3) Injector O Rings are leaking slightly. Maybe its not something that would be noticed at regular rpm or lower boost, but maybe that extra PSI is causing one of them to come unseated. I dont smell fuel though and I dont see any residue around them. Apparently I can pressurize the intake and then spray soapy water on them to see if they are leaking.
4) Fuel Pump is going. Its got 25k on it and the walbro's have been known to fail randomly.. maybe its time for a new one now that Im asking a lot of it.
5) Injectors not spraying correctly at that high a flow. IDC wasn't that high though. ~53% when it started to fail. And wouldn't that cause knock due to going to lean?
6) Some sort of cam timing issue. I cant think of when it would have skipped a tooth though and the T belt was done 25k ago.
7) Gremlins. I must have fed them after midnight.

My current favourite explanation is the coilpacks. Conveniently, they're easy to check. Just gotta find a set and swap em. I'll do the spark plugs (swap to 7EIX) at the same time. Its cheap and then Im sure Im running the correct ones.
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Old 11-04-2012, 07:04 PM   #67
Zaider
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Well. I went and washed the car so I figured that I might as well get a couple pics if I could.


DSC_3316 by zcherniawsky, on Flickr


DSC_3320 by zcherniawsky, on Flickr


DSC_3323 by zcherniawsky, on Flickr

Sigh. Winter mode sucks.
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Old 11-04-2012, 09:13 PM   #68
brett192
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Car looks clean, basically my goal with my car. Nice work
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Old 11-05-2012, 12:21 AM   #69
Cranker625
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Nice looking car
I wish my bugeye was black, they look so much meaner.

What tire size are you running? They look like 235?
looks beefier than my puny 225s
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Old 11-05-2012, 01:00 AM   #70
Zaider
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Car looks clean, basically my goal with my car. Nice work
Thanks. Its gone through a lot of iterations to get to this point.. and there's lots of parts sitting in the garage waiting to go on. The goal is simple, clean, aggressive.

Quote:
Originally Posted by Cranker625 View Post
Nice looking car
I wish my bugeye was black, they look so much meaner.

What tire size are you running? They look like 235?
looks beefier than my puny 225s
Thanks

They're 225/45/17 Nokian Hakka R's on a 17x8.
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Old 11-05-2012, 11:26 AM   #71
rs420
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Always a beauty.

Love the winter setup.

How's she been running since your tune a few months back?

Calgary roads still holding up ok ?
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Old 11-05-2012, 12:29 PM   #72
Zaider
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Originally Posted by rs420 View Post
Always a beauty.

Love the winter setup.

How's she been running since your tune a few months back?

Calgary roads still holding up ok ?
Thanks! Got some changes coming up. Looking at a different front lip and going air suspension next spring. Also have a set of chargespeed brake ducts that I'll wait until spring to install. I'll also be repainting at least the front end of the car as I try to get rid of some rock chips and sand blasting. Finally there's the Aquamist kit that needs to be installed.

Its still got the temporary tune to 280whp (limited to 18psi) because I had knee surgery and didn't have time to get retuned before winter hit. The tune is fine.. just lacks power.

I tracked down the slight misfire issue to coilpacks that were going bad. The theory is that I slightly fried them when I had a grounding issue a while back. Just enough so that at peak load (high boost/5000rpm) they couldn't spark properly and the engine would misfire slightly.

The plugs and coilpacks have been replaced and Im just figuring out a time when I can bring the car down to the shop and get retuned. When I do that, I'll be swapping to a short ram KS tech 73mm intake. Im not sure if I mentioned it before, but I'm using the stock airbox with no snorkus, drawing air straight from the fender. Because Im so low, I can't run fender liners without rubbing so the air box would suck in snow, slush and rain until I hydrolocked the engine. My temp fix was to dremel a hole into the air box so I draw air from next to the ABS control solenoid and block off the air from the fender by sliding a mudflap (which i dont use anymore) in between the air box and the fender. I definitely suffer some power loss, but its better than sucking water into the engine.

So anyway, I'll use the KS Tech Intake. Its got a massive filter and I'll use the intake ram horn to flow air directly to the SRI filter and hopefully fab up a heat shield to keep hot air away.

Calgary roads... ha ha. I was driving yesterday and kept hitting the Beatrush undertray on ridges in the road and crunched my front bumper as a wheel went into a pothole. I think I might need to redo the zip ties that are holding onto the front bumper.

Hopefully I can plan a trip out to the island next spring/summer. Id like to swing by a VIC meet and put some faces to names.
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Old 11-08-2012, 02:59 AM   #73
alcoolaid
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Well let us know when you come into town! I'd definitely like to check out this ride.

I heard from my friends in Edmonton that they just got a dump load of snow, having some fun on the roads yet?
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Old 11-10-2012, 08:46 PM   #74
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Wow, that's a nice build man.

I'm at a loss for words! Come show us your car!
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Old 11-15-2012, 11:18 AM   #75
Zaider
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Originally Posted by alcoolaid View Post
Well let us know when you come into town! I'd definitely like to check out this ride.

I heard from my friends in Edmonton that they just got a dump load of snow, having some fun on the roads yet?
And I want to see your car

Yeah, we got about a foot of snow in 24 hours last week. The roads were fun and I took any excuse to go out and play. "What? We need milk? Back in 3 hours."



Quote:
Originally Posted by DIGGYGV8 View Post
Wow, that's a nice build man.

I'm at a loss for words! Come show us your car!
Thanks. I appreciate that.


I've been trying to find a time with my tuner, Airboy, to get the car in and the tune finished. I'd really like to install the 73mm intake.
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