Start Her Up - Forged 4G15 MiVEC

So I started it up and did the 20min breakin. AFR were all over the shop, but that is because its hard to hold the rpm.  I have to bounce the rpm and not let it idle.


Trying to find the right washer for the banjos.





Oil temps were getting high, about 180F, oil pressures were lower than expected :(
That could be because of 5W-30 mineral oils. I used the Joe Gibbs, Driven oils for the 20mins.

I run an external gate, I decided to make a divider on the dump housing.





I'm not a welder, but it will suffice.


I spoke to the engine machinist, he said the first 20mins was the most critical.  Hence, I used the good stuff for the first 20mins
I will be using some Penrite 15W-40 Running In Oil for the road km.








I put the flanges on the linisher.
My first time using it. Took ages to setup.

I put the engine in solo, pain in the ass if you have the A/C unit in there. So that was removed.

A/C weight about 7-8kg. Not much.










Time to hang the manifold and torque it down.











The housings on the turbo needed to be turned slightly. I draft mounted the FMIC to work out the best angle or rotation.






In goes the radiator.  As you can see, the plastic shield was melted.  I believe it was from my track days that don't have a cool down lap :(

Slowing going together.  I'm a slow worker, but I try to do it right.












I drilled out the spot welds on the bonnet catch.










FMIC was mounted, radiator and supports are in.
Only the wiring was left to tidy up.
Exhaust and turbo is in.

35 Days - Mission Impossible

Approx 4weeks, 35 days between my two races I decided it was time to swap the motor, install a bigger turbo, custom 3" exhaust, breakin and get it tuned.  A proper tune is out the door as the tuner is overseas :(

How does one remove a jammed solenoid, you use a slide hammer. Causing some damage to the soft ally.





When I say 35days, realistically its 4 weekends, minus a few weekend days as I work other jobs + M-F I'm at work.
I'm hoping the exhaust is still an option, the flex pipe is completely gone.  The exhaust guy will try slot me in when it is up and running.







A road tune will have to suffice for the next track day, touch wood we can get all the bugs out.

So many little things to consider when swapping engines, like the clutch.  It didn't look too good.
I can't see it living much longer :(





The mivec solenoid had a lot of issues.  In the process of removing the oil balls the bore of the solenoid got damage. I needed to hone it out.  Something I didn't consider after the head was already on.
I have yet to know if this will cause any issues coming up.

The motor to go in.


Current setup with the old motor. Minus the hood. So it begins!

Slowly getting there.

The old vs. the new. Chibi workshop is looking a bit full.














My modified manifold doesn't have gaskets, so I will reuse my old one.


















My old turbo, 4yrs? TD04 for $150.
It still has a chipped exhaust wheel.









I needed some parts of my running motor to finish the forged motor. E.g. alternator, intake, throttle body, timing covers.









The magical workbench.


























I made a bracket to remove the crank pulley bolt, failed :( So I made a stronger one, not seen here.
It worked :)










 Relocating the oil sandwich plate.











 RRP pulleys I had on the shelf for a couple years.
Why? Because I can. I needed to order something big from RRP, so I added a few other items.








 

Rear main install is last, as it is blocked by the engine stand.











The fly wheel and its hot spots :(
The clutch disc










Ahhhh...Not enough material, I hit each pad with a diamond file to remove the glaze.

Moved the old clutch and fly to the new motor.