Re: Russianred's Turbo Build Thread! *UPDATED 9/21/11*
Mega build update.
Worked all last week to get to this point.
Gotta clean that fan before installing the modified enclosure onto the half-size radiator.
You know what it is..
The mounts I had all taped off and ready to pour, and at the last second I could not get anyone to come through with letting me use their oven for 12 hours.. These won't smell or burn anything up, especially not at their curing temperature of 160F!! C'mon people.. I woulda paid for the electric expense too but couldn't find anyone to let me do it.
View of the shop where all the work was done, and sleepless nights were spent in solitude and determination.
Donor F23A1 engine, every piece on it is PERFECT. If anyone needs anything from it, it's all in my FOR SALE thread. I only used the block.
My original head on the workbench, waiting to be cleaned up a bit and installed on the 'new' block.
My old block, with tranny in the rear passenger seat of my car before we took it out and dissected it.
This is how I modified the OEM fan to fit the half-size radiator for my setup. Width-wise, it actually fit perfectly, after I cut away the necessary material for it to fit where it needed to go. It uses an extended factory plug for operation, as does the slim-fan on front. Both fans worked perfectly after we started up and tested the car.
Tranny with the old block on it getting ready for the switcheroo.
Surplus head.
Donor block getting ready for assembly.
Some shots of the timing and gears inside. After my project here, I will never ever pay for a timing job.. It is just too simple.
Donor block mated with original tranny, and ready to swap into the car. Process of swapping it in.
Bustin a sweat, and breaking vessels as we install the head onto the bolted in block. Was a little more difficult with the IM and turbo bolted onto it.. Lining up the coolant channel dowels and head gasket were a
bitch, but we figured a trick to do it. To align easiest, put two head bolts into the back left and right holes (dowel holes), then lift the head gently, let bolts drop into needed holes, and gently lower. After figuring out how easy it is done, I was wondering why we spent so much time trying to do it otherwise!
Tweaking some stuff around. That is my second change of clothes in 4 or 5 days, I was smellin pretty fresh at that point.
Outside - pretty much ready to start it.
My friend Kenny plugging up the boost controller hose to the turbo housing bung.
Outside.
Some engine shots. Unfortunately we didn't have time to paint the bay itself, it would have looked much better. We did however polish as many parts as possible including left and right engine mount brackets, starter, alternator, and power steering bracket and pump.
Some shots of a little something extra I did. I tucked away my whole engine harness under the intake manifold, and only had to extend the EGR plug. The rest had perfect lengths as if they were specifically made for this! I must say though, that in a prior build, I had to solder on OBD1 clips instead of my OBD2 OEM ones, and their length could have been longer since I extended the wires there beforehand, and now I didn't have any length problems. If any of you want to do this, all you will have to extend is EGR, and the 4 injector plugs. Everything else reaches. For a future endeavor, I plan to likewise tuck the headlight harnesses that run along either side of the car, this should be just as simple if done correctly.
So we got the car running, but it won't drive. Anytime it's put in gear, it stalls. Also when idling and giving it gas, it hesitates above 2000RPMs. We checked the timing so many times - it's perfect. Plugs are good. Wires work well. i am guessing that electronic timing is off, and if this is the case all the car needs is a tune. I have decided to upgrade from the P28 setup, to a full standalone AEM EMS. Along with a good basemap, I can get it tuned here locally for $200. Already talked to my friend who knows the tuner, and we will get the ball rolling with the tune within these 2 weeks.
Comments and questions appreciated!
