Oil Cooler? Stainless Fuel Lines? Conversion to AN Fittings for the RColt

Previous install of the fuel pump - /fuel-pump-install-z27ag.html
Then i had to move the reg for the MCS install /cusco-mcs-for-z27ag-fuel-reg-move.html

I have to relocate the Tomei Type S fuel reg so that i can install the Cusco Master cylinder stopper.

Fuel Reg Specs Tomei becareful of fakes
Tomei 185106 Fuel Pressure Regulator Adapter Nissan Subaru Toyota
Accessories:
- 2x AN6 to 1/8NPT (fuel reg side) Fitting
- 2x #8 Straight / 1/8NPT Fitting [in use at the moment]

My friend uses a Sard fuel reg. Looks like they also use the same fittings AN6 to 1/8NPT




Fuel Rail Adapter Specs
The fuel rail adapter used is the same one for the Skylines series.
I believe the actual item i use is from the RB26DETT BNR32/BCNR33/BNR34 (which has the ability to use AN6 fittings).
- 11mm diameter fuel rail insert nipple, 10mm long
- NPT1/8 thread
- 40mm bolt to bolt with 3.5mm movement







Current Setup
I have upgraded the fuel pump and have a Type S Tomei fuel reg, also with barbed fittings.
At the moment i am using a barb outlet 8 mm / 0.314 inch on the  1/8" female ports of the fuel reg.
Therefore i need 2x AN6 to 1/8NPT (fuel reg side) fittings
Fuel Hose - 5/16", 7.9mm






This is what i asked for - 
 - 4 x AN6 to 1/8NPT - fuel reg/fuelrail adapters
 - 4 x 6AN male to 5/16" tubing adapters (p/n: 165056ERL) - for fuel delivery hard line connection
 - 10 x 6AN female to -6AN hose adapters (p/n: 300106ERL) - join the hoses to the -6AN male fittings e.g. fuel reg in/out to fuel rail and fuel return
 - 3.5M x 6AN hose (200series PTFE for all fuels)
 - 1 x inline 6AN fuel filter

All up it costed about $300AU, I should have plenty of left overs to do two cars.

This is what i got - 
 4 - AF816-06-02 - Male flare -6an to 1/8" NPT
 4 - AF108-05 - 5/16 tube to male -6an adapter
 10 - AF101-06 - straight hose end -6an blue
 1 - AF200-06-4.5M - SS Teflon Braided hose -6an
 1 - AF609-06 - billet fuel filter -6an

Tools
- Wurth pipe sealer or equivalent e.g. Loctite liquid thread seal - used for the NPT threads not AN fittings
- 6AN Earl's 165056 - Earl's Hard-Line AN Tube Fittings
- Koul Tool
- Earl Fitting Tools e.g. vice holder
- 37 degree flaring kit
- AEROFLOW BILLET VICE SOFT JAWS ALLOY AF98-2001 - AU $37.20





Brands

There are a few brands of different fittings, some include:
- Russell
- Weiand
- Earl's
- Allstar
- Aeroquip
- Aeromotive
- JEGS
- MagnaFuel





Earl / Edelbrock Parts
- Earl's -6AN male to 5/16" tubing adapters (p/n: 165056ERL) - for fuel delivery hard line connaction
- Earl's -6AN female to -6AN hose adapters (p/n: 300106ERL) - join the hoses to the -6AN male fittings e.g. fuel reg in/out to fuel rail and fuel return (need 4 of these min)
- -6AN hose
- some fuel regs can be a 3/8 NPT therefore these use -6AN male to 3/8" NPT (p/n: 981666ERL) to adapt the 6AN female hose end to fuel pressure regulator
- my Tomei Type S fuel reg is a 1/8 NPT therefore Earl's (p/n: 981662ERL) -6AN to 1/8NPT FPR Adapter
- Edelbrock fuel filter w/ -6AN male ends (p/n: 8129)

Stock and Hardline Fittings At the moment i am trying to find a decent hard line fitting adapter (e.g. 165056ERL). Earl does one but I am also looking into Swagelok see here. 
Using the Earl fittings good for ~60psi http://www.anplumbing.com/page/16
You might also hear about yor-lok tube fittings which i believe are double ferrule compression fittings

I also came across an Aeromotive 15103 - 5/16'' MALE QUICK CONNECT TO AN-06 MALE

Installation Notes
extracted from stealth316
Assemble the AN fittings and adapters. AN fittings seal either by the close contact of the 37º flared ends or with o-rings. The threads themselves never seal AN connectors. Also, never use thread sealant or tape on AN threads. e.g. not supposed to use Teflon tape on AN fittings.

o-rings, you can buy from either Aeroquip or Earl's. Either BUNA-N synthetic rubber or Viton will work. Both compounds are compatible with most fuels. However, Viton is more scuff resistance, can last longer, and has a higher temperature rating (400ºF instead of 275ºF for the BUNA).

SS braid coupled with movement can wear through areas in your engine bay. Make sure it is not in contact with hoses or parts that could cause damage. I put wire loom on some of my lines.

Earls
"Fuel manufacturers may have added any number of new unpublished additives to their blends. It is therefore difficult to know how the tube compound used in the inner liner of our Perform–O–Flex or any other brand of elastomeric hose will react with a specific fuel. Because of the unknowns described above, we are unable to guarantee that the hose listed is the best possible product to use with any specific fuel. If in doubt use teflon lined hose. Not to be used with brake fluid". 

HondaTech Forums

Background on AN and NPT
http://www.anplumbing.com/page/1
"AN" (Army-Navy) Sizes were established by the Aerospace industry years ago and were designated O.D. of the rigid metal tube that each size fitting is used with. 
AN sizes range from -2 (dash two) to -32 in irregular steps, with each step equating to the OD (outside diameter) of the tubing in 1/16" increments. Therefore, a -8 AN size would be equal to 1/2" OD tube (8 x 1/16 = 1/2). However, this system does not specify the ID (inside diameter) of the tubing because the tube wall can vary in thickness. Each AN size also uses its own standard thread size.
Note that 37° AN and 45° SAE fittings and tooling are not interchangeable due to the different flaring angles. Mixing them can cause leakage at the flare.

"NPT" THREAD SIZES:
Some of the most popular adapter fittings shown in our on-line shop are AN to NPT adapters

Oil Filter Relocation

Oil Filter - Ryco Z436
Height Overall 66.00mm
Seal Diameter 64.00mm
Seam Diameter 69.50mm
Thread M20-x1.5-6H

Earls Oil Filter Relocation:
MITSUBISHI ALL MODELS 78-2002 VARIOUS
THREAD - M20 X 1.5
SANDWICH - 517
BYPASS - 1977
REMOTE - ANY

I got a quote on the AF64-2042 to do an oil filter relocation swap. But it was way to expensive plus it didn't have a thermostat $200+.

Other Thing on the Shopping List

Aeroflow Billet Radiator Filter/Filler - Part # AF64-2043

Grex Oil sandwich cooler adapter P#12401126
M20 x 1.50 -10AN Fittings (2 in & 2 out)

The thermostat open temperature ranges from 71deg~85deg Celcius.

Note: 3/4x16unf filter Required. The Female side going to the block will be M20x1.5, but the male side going to the filter will be 3/4x16UNF (which is a common thread on Nissan oil filters e.g. Skylines)

Possible Ryco filters (similar to the Z436):

                Height Overall Seal Diameter Seam Diameter

Z386 76.00mm         63.00mm         68.00mm **Closest to seal spec

Z443 66.00mm         66.00mm         71.00mm **Closest to height spec

Earl s Performance 502ERL Adapter, Oil Filter, Sandwich, Aluminum, Natural, 3/4-16 in. Thread, -10 AN O-Ring Inlet/Outlet

Manufacturers
http://www.aeroflowperformance.com
http://www.earls.com.au
http://www.anplumbing.com
http://www.hamburgersperformance.com/

Stripping Down A Broken Block - 4G15T

< My car :) Sleeping :(

If you have been following, a mate and I are in the process of building another 4G15. A recent discovery in the old crank was a gouge. We are not happy with it. It could be fine, it may not be fine.




Close ups of the head












More details here: /4g15-crank-installation-arp-main-studs.html
I bought a wreck awhile back under the impression the engine was fine. BUT! It was not, i think i got cheated. Under the timing covers was a cracked block :(
This is the tear down of that motor.





























I played around with my torque bar and tried to gauge how much more torque was required to get the head bolts to slip. I was just shy of 80nm. Sitting around the 70nm. The stock OEM bolts are measure by degrees and not nm.




Oil line from pump to head.




















The head had been sitting a long time. The head gasket is damaged due to the broken block.










Correct installation of the gasket







Back and side profiles of the engine.














Oil pump and water pump



















Sludged motor, prob from blown water jacket and been sitting for many years.























Crank looked ok from first impressions































Broken block :(
Another broken block here:
/4g15-mivec-long-block-disassemble.html


Diagram:
http://demo.saleepc.ru/mitsubishi/groups/gen/B80A2001A/Z27A/XNGFR8

Main Studs:
Mitsubishi 6 Bolt 4g63 (6 Pack) MD000235
10 BOLT,CYLINDER BLOCK FLANGE,10X69

OEM Crank Bearings:
 03018 MD332492 2003061 2004113
03018 MD332493 2003061 2004113
03018 MD332494 2003061 2004113
03018 MD332495 2003061 2004113
03018 MD332496 2003061 2004113
03018 1052A016 2005121
03018 1052A017 2005121
03018 1052A018 2005121
03018 1052A019 2005121
03018 1052A020 2005121


Big End Bearings:
03019 MD370354 2003061 2004113
03019 MD370355 2003061 2004113
03019 MD370356 2003061 2004113
03019 1115A081 2005121 2007123
03019 1115A082 2005121 2007123
03019 1115A083 2005121 2007123
03019 1115A084 2005121 2007123
03019 1115A085 2005121 2007123
03019 1115A423 2008011
03019 1115A424 2008011
03019 1115A425 2008011
03019 1115A426 2008011
03019 1115A427 2008011

Thrust Bearing:
03068 MD332719 2003061 2004113
03068 MD332720 2003061 2004113
03068 MD332721 2003061 2004113
03068 MD332722 2003061 2004113
03068 MD332723 2003061 2004113
03068 1052A021 2005121
03068 1052A022 2005121
03068 1052A023 2005121
03068 1052A024 2005121
03068 1052A025 2005121

Camskill Lifter Information:
MODEL NAME: MITSUBISHI TAPPETS/LASH ADJUSTERS - Tappets/Lash Adjusters X 8 - MD171130 MD376687

CA3A CB3A MIRAGE/LANCER 4G91 DOHC
CA4A MIRAGE 4G92 DOHC (NON MIVEC)
CB6A MIRAGE/LANCER 6A10 DOHC
CD5A CD5W LANCER/LIBERO 4G93 DOHC TURBO
CJ2A CK2A MIRAGE/LANCER 4G15 DOHC
CM5A MIRAGE/LANCER 4G93 DOHC TURBO
CQ2A CS2A MIRAGE/LANCER 4G15 DOHC
CQ5A CS5A MIRAGE/LANCER 4G93 DOHC
CU4W AIRTRECK 4G64 DOHC
DA2A CARISMA 4G93 DOHC
DE3A FTO 6A12 DOHC (NON MIVEC)
E52A GALANT 4G93 DOHC
E54A E64A E74A E84A GALANT 6A12 DOHC
EA1A EC1A EA1W EC1W GALANT/LEGNUM 4G93 DOHC
EA3A EC3A EA3W EC3W GALANT/LEGNUM 4G64 DOHC
EA7A EC7A EA7W EC7W GALANT/LEGNUM 4G94 DOHC
EC5A EA5W EC5W GALANT/LEGNUM 6A13 DOHC
F36A F46A DIAMANTE 6G72 SOHC
N61W N71W RVR 4G93 DOHC
N64WG N74WG RVR 4G64 DOHC
N84W N94W CHARIOT 4G64 DOHC
S33A S43A PROUDIA 8A80 DOHC
Z25A Z26A COLT 4G19 DOHC MIVEC
Z27A Z28A COLT 4G15 DOHC MIVEC

Notes 1 These are 3mm hole type

Manufacturers Part Numbers for REF ONLY CAMSKIT2093
MD376687
MD377239
MD171130
MD359419

4G15 Crank Installation - ARP Main Studs and ACL Bearings 5M1124 (Half Groove)

If you saw early i hit a snag getting the crank in
/4g15-bottom-end-main-stud-install-arp.html
I managed to get the crank in today (day two of the build). I stripped all the studs out, thread chased the block again and cleaned all surfaces.
I installed the studs, torqued down the main caps and measured all the main journals.

Part of the process i go through is zero all instruments before i begin. A vice comes in handy when holding the micrometer and using it to set a dial bore gauge.










Measuring main journals.






















I was using telescopic gauges but i found they weren't reliable and giving a fair amount of difference in results. I believe it could be due to the face that i was using it outside of its comfort range.
They are max 54mm and i am trying to measure 52mm.








I setup the dial bore gauge with a 50mm tip and a 3mm spacer.









Install grooved bearings to the cylinder block.
NOTE: Center bearings (with thrust flanges) are
grooveless.
Install grooveless bearings to the bearing caps.









After fitting the bearing caps, measure the end
play in the crankshaft. If the measurement
exceeds the specified limit, replace the crankshaft
bearings.
Standard value: 0.05 − 0.18 mm
Limit: 0.25 mm






On the bottom surface of each bearing cap is the

capís number and an arrow. Starting at the timing
belt side, fit the bearing caps in numerical order.
Ensure that the arrows point toward the timing
belt side.





This plastic gauge method is recommended as the simplest way of measuring the crankshaft oil clear-ance. Measure the crankshaft oil clearance using a plastic gauge as follows:

1. Wipe off oil from the crankshaft journal surface and the crankshaft bearing inner surface.
2. Install the crankshaft.

3. Cut a piece of plastic gauge whose length is
equivalent to the width of the bearing and place it on the crankshaft journal in parallel with its axis.
4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque according






5. Remove the bolts, then remove the crankshaft bearing cap carefully.
6. Measure the largest width of the crushed plastic gauge using the ruler printed on the bag of the plastic gauge.
Standard value: 0.02 − 0.04 mm
Limit: 0.1 mm







NOTE: The crankshaft pins and journals are fillet-rolled and must not be machined to undersize dimensions.









I measured all the crank journals. Both x and y axis and also left and right of the oil feed.
Removed the main caps and installed the bearings with plasti gauge.
I had calculated the oil clearances already. I will post them up late. But i was looking for a .02-.04mm oil clearance.




















I wanted to accomplish something hence i went ahead and installed the crank. It might have to come out again, i am not sure. I hope not.






CRANKSHAFT AND CYLINDER BLOCK (LIMIT)
Crankshaft end play mm 0.05 − 0.18 (0.25)
Oil clearance at crankshaft journals mm 0.02 − 0.04 (0.1)
Cylinder block gasket surface warp mm 0.05 (0.1)
Cylinder block gasket surface grinding limit
(including cylinder head grinding amount) mm  − (0.2)
Cylinder bore diameter mm 75.50 − 75.53 (−)
Taper of cylinder mm 0.01 or less (−)
Cylinder-to-piston clearance mm 0.02 − 0.04 (−)
























OEM Bearings - unusual wear i think

























ATM i am thinking of crocus cloth vs emery cloth to just remove any high spots.

Block Markings were 11111 (hence no1 to no5 all came in the same)
Journal diameter mm 47.988 − 47.994
Bearing identification mark 3
Crank Markings 22222
                        ABBB1

Working out sizes /selecting-bearing-piston-sizes-for.html
See more about the bent rod here /bent-rod-z27ag-4g15-more-to-come.html
Bearing picklist /rcolt-rebuild-pick-list-part-numbers.html
Assembly specs /z27a-4g15-engine-re-assembly-torque.html

--- A ding i saw in the crank. Makes me wonder if it was polished @_@

WISECO PISTONS SPECS
Suggest Clearance on Piston Kit Spec sheet is 0.0035 (0.08889999999999999mm)
Spec sheet 1: Bore 2.9920" = 75.9968mm (.5mm oversized)
Spec sheet 2: Bore 3.0120" = 76.5048mm (1mm oversized)











CYLINDER BLOCK
1. Visually check the cylinder block for scratches, rust, and any other corrosion. Also check it for cracks using a flaw detecting penetrant. If any defect is evident, replace the cylinder block.





2. Use a straightedge and thickness gauge to check the cylinder block top surface for warp. If the warp exceeds the specified limit, correct by grinding.
Make sure that the surface is free from remaining gasket material and other foreign matter.
Standard value: 0.05 mm
Limit: 0.1 mm
Grinding limit: 0.2 mm
3. Check cylinder walls for scratches and seizure. If defects are evident, rebore to oversize or replace the cylinder block.
4. Use a cylinder gauge to measure the cylinder bore diameter and taper. If the cylinder is worn badly, rebore it to an oversize and replace the piston and piston rings with ones matched with the new bore size. The points at which the measurements should be made are indicated in the illustration.
Standard value: 75.50 − 75.53 mm
Taper: 0.01 mm or less

BORING CYLINDERS
1. Select an oversize of the pistons to be used based on the largest of the cylinder bores.
2. Oversize pistons are available in two oversizes 0.50 mm and 1.00 mm. Bore each cylinder to a size that provides the standard clearance when combined with the selected piston. The reference position for piston diameter measurement is as shown in the illustration.
3. Based on the piston diameter measurement, calculate the boring finish dimension.
• Boring finish dimension = [Piston diameter] + [0.02 − 0.04 mm (clearance between piston an cylinder)] − [0.02 mm (honing margin)]
CAUTION
To prevent deformation of cylinder block that would result from the heat generated by boring bore the cylinders in the following sequence:
No. 2 → No. 4 → No. 1 → No. 3.
4. Bore all the cylinders to the calculated boring finish dimension.
5. Hone the bored cylinders to the final finish dimension (piston diameter + clearance between piston and cylinder).
6. Check the clearance between the piston and cylinder.
Standard value: 0.02 − 0.04 mm