Stage 3 - Measuring & Ring Gapping - 6hrs

The fun continues...

Ring Gapping, Cleaning, Timing Gear, Oil Pump Inspection.
The list is forever long.
Porting, Turbo Tear Down VF34.

/stage-1-block-cleaning-4hrs.html
/stage-2-block-cleaning-crank-install.html

-----Diametric Ring 7600XX------

Bore Size (In.) = 2.992

Bore Size (MM) = 76.00

Ring Width (thickness, 1st, 2nd & 3rd) = 1.0mm-1.2mm-2.8mm

Top Ring Type = Gas Nitrited

Top Ring Code = SGP . . Steel . .Gas Nitrided . . Positive Twist

2nd Ring Code = IPN  . .  Cast Iron . .Phosphate . . Napier Scraper

Oil Ring Code = CUS . . Steel . . Chrome . . Std Tension

Oil Ring Tension = std 

# in Set = 1

Set Part Number = 7600XX

Piston Ring Breakdown:

Top Ring : 1mm (.039") / Alloy steel / Gas Nitrided / barrel faced

2nd Ring : 1.2mm (.047") / Cast iron / Phosphate coated / Taper faced / Napier hook

Oil Scraper: 2.8mm (.110") / 3-piece oil assembly / Stainless stl. flex-vent spacer / Gas nitrided rails

I think they recommend a 400grit on the finish hone.

XX / XC SETS 1.0 1.2 2.8 RING PACK

Ring sets for popular aftermarket sport compact pistons using the 1.0 1.2 2.8 ring pack.

         GAPLESS®    GAPLESS®    CONV

  BORE   TOP RING    2ND RING    RING

  76MM    M2992XC    T2992XC    2992XC

 2.992”

 76.5MM   M3012XC    T3012XC    3012XC

 3.012

----

  76MM    M2992XX    T2992XX    2992XX

 2.992”

 76.5MM   M3012XX    T3012XX    3012XX

 3.012”

 XC < XX ( XX has more tention on the oil rings)

I think Wiseco recommend a 400grit on the finish hone.

E85 Plans - Fuel Pump & Injectors

My Mate Uses: ID1000.18.02.48.11.4

Injector Dynamics Codes:
48 = Length
11 = Diameter
04 = Qty
18 = Car Make ID
02 = Car Model IDSize - 14mm

Nominal Flow Rate – 
1015cc/min @ 3.0 Bar (43.5 psi) Using Gasoline at 52 Degrees C (125 Degrees F)
Maximum Differential Fuel Pressure –
7.0 Bar (101.5 psi)
Fuel Compatibility – 
Compatible With All Known Fuels
Electrical Connector - 
USCAR

Most injector applications fall into one of four standard fitments consisting of two standard lengths, (48mm or 60mm) and 2 standard fuel rail bores (11mm, or 14mm)

Our ones can be found in:
WRX (02-11) / STi (07-11) e.g. 725.18.02.48.11.4

------------------

OEM Subaru Units:
baby blue' = 05 WRX = 440cc.
pink = STi = 550cc.

------------------
Injector cushions / orings (basically comes in a standard rebuild kit) ---> Top feed uses these
------------------

Fuel injectors are a direct fit for Subaru applications with top feed fuel injectors which can be found on Subaru WRX 2002-2014, Subaru STI 2007-2015 as well as other Subaru models with top feed (not side feed) fuel injectors.  Fuel injectors are also considered an upgrade for other applications such as Mazda Miata, Mazda RX8/RX-8, Mitsubishi 3G Eclipse (2000-2005), etc.  Fuel injectors are high impedance/saturated.

------------------


A long time ago i ordered a bunch of AN fittings to redo my fuel reg etc.
This time I hope to actually do it, i got the hardline adapters to AN6.
/oil-cooler-stainless-fuel-lines.html

I have used AF808-02 = LS1 5/16" Push On Fitting
I wanted to have a clean setup hence these fuel rail adapters will come in handy.

Current Fuel Pump: /fuel-pump-install-z27ag.html



I also picked up a new pump just encase (E85 Ready)
DeatschWerks DW300 Fuel Pump - Suit Mitsubishi - E85 Safe 4G63
Mitsubishi EVO 8/9 2003-2007
Pump w/ Kit = 9-301-0847



Pumps fits the same profile as a Walbro GSS342 for a simple drop-in installation

With the large pump, I will require a larger fuel reg, possibly might end up with a TurboSmart Unit.

------------------

What about my flex fuel sensor?
What are the sizes of the flex fuel sensor inflow and outflow lines?
Zeitronix Flow Through Flex Fuel Sensor both tubes are 0.37" and 0.5" at the flange.
Which translate to a 3/8" hence I need two AN6 MALE to 3/8" FEMALE QUICK CONNECT

Pretty Good Read:
/3580-Zietronix-ECA-2-(ethanol-content-analyzer)-install

He uses Russell Fittings, I am using AeroFlow...
 - Russell 644123 -6AN Male to 3/8" SAE Fitting
 - Russell 644113 -6AN Male to 5/16" SAE Fitting
 - Radium PTFE -6AN Hose Assemblies

Evo VII 320mm Rotor on a Ralliart Colt? Tell me more...

I made my upgraded brakes to suit an Evo rotor because of the multiple brands. I have purchased some GiroDisc 320mm for an Evo & some ProjectMu Pads.

All can be reviewed here: /rcolt-4pots-ucf30-rebuild-running-gear.html










Project Mu Type HC - F110 brake pads and new PS-F110 shims.
Pad measure in at ~115mm wide and ~60mm tall.
PMu quotes it at 118.5mm wide.






/lexus-ucf30-monoblock-to-ralliart-colt.html






I used another 5stud Evo rotor as my template. When converting a 5 stud to a 4 stud, one stud is in common.

ACL Closed Down - What Now - 4B1130 & 5M1737 Alternative

I previously covered bearings here: /rcolt-rebuild-pick-list-part-numbers.html
But after receiving some TDC (China/Taiwan) bearings over a much wanted ACL unit, I wasn't happy.
TDC using the ACL part number :(
So I been researching cross referenced part numbers, I want some Taiho units but I can't find a way to get a hold of them. PLUS some people report they were opening a manufacturing plant in China.
Last choice if I can't accept the TDC unit is to get OEM.

Previous bearing install: /4g15-crank-installation-arp-main-studs.html

ROD BEARINGS - MITSUBISHI MD143090

------------------------------------------------

MITSUBISHI COLT Mk II 1.5 GLX (C12A) 1468 51 4 Hatchback 1985-1988
MITSUBISHI COLT Mk II 1.5 GLX (C12A) 1468 55 4 Hatchback 1984-1988
MITSUBISHI COLT Mk III 1.3 GL (C61A) 1299 44 4 Hatchback 1988-1990
MITSUBISHI COLT Mk III 1.5 GLXi (C52A) 1468 62 4 Hatchback 1988-1992
MITSUBISHI COLT Mk III 1.5 (C52A) CAT 1468 66 4 Hatchback 1990-1992
MITSUBISHI LANCER Mk III 1.5 GLX (C12AS) 1468 51 4 Saloon 1985-1988
MITSUBISHI LANCER Mk III 1.5 GLX (C12AS) 1468 55 4 Saloon 1983-1988
MITSUBISHI LANCER Mk III 1.5 (C12V) 1468 51 4 Estate 1985-1989
MITSUBISHI LANCER Mk III 1.5 (C12V) 1468 55 4 Estate 1985-1987
MITSUBISHI LANCER Mk III 1.5 (C12V) 1468 61 4 Estate 1988-1990
MITSUBISHI LANCER Mk IV 1.3 (C61A) 1299 44 4 Saloon 1988-1992
MITSUBISHI LANCER Mk IV 1.5 (C62A) 1468 62 4 Saloon 1988-1992
MITSUBISHI COLT Mk II 1.3 EL,GL (C11A) 1299 49 4 Hatchback 1986-1988

------------------------------------------------

Cross Reference Rod Bearing Numbers:
JAPANPARTS CB1825A
ASHIKA 82-1825A
JAPKO 21825A
KOLBENSCHMIDT CB-1825A STD
SEALED POWER 4-4475RA
JAPANPARTS 82-1825A
ASHIKA CB1825A
ACL 4B1130 STD

------------------------------------------------

MD143090 01 BEARING SET,CONNROD PLAIN,STD
MD143091 CC BEARING SET,CONNROD PLAIN,U/SIZE 0.25
MD143092 CC BEARING SET,CONNROD PLAIN,U/SIZE 0.50
MD143093 CC BEARING SET,CONNROD PLAIN,U/SIZE 0.75

------------------------------------------------


MAIN BEARINGS:
MITSUBISHI MD030126
KOLBENSCHMIDT MS1818ASTD
AE AEM5463STD
ACL 5M1737STD
FEDERAL 6630MSTD
MITSUBISHI MD030126

------------------------------------------------


MitsubishiColtZ27AGXNGF RA VER-R (Turbo/2WD), 5FM/TEnginePiston & crankshaft:

QTY NEEDED = 4 {MAINS}
1052A016 BEARING,CRANKSHAFT PLAIN,STD 1 BROWN
1052A017 BEARING,CRANKSHAFT PLAIN,STD 2 N0NE
1052A018 BEARING,CRANKSHAFT PLAIN,STD 3 BLUE
1052A019 BEARING,CRANKSHAFT PLAIN,STD 4 YELLOW
1052A020 BEARING,CRANKSHAFT PLAIN,STD 5 GREEN

QTY NEEDED = 1 {THRUST}
1052A021 BEARING,CRANKSHAFT,CTR PLAIN,STD 1
1052A022 BEARING,CRANKSHAFT,CTR PLAIN,STD 2
1052A023 BEARING,CRANKSHAFT,CTR PLAIN,STD 3
1052A024 BEARING,CRANKSHAFT,CTR PLAIN,STD 4
1052A025 BEARING,CRANKSHAFT,CTR PLAIN,STD 5

...................

QTY NEEDED = 4 {CONROD} MANUF PERIOD 2006.05.1 - 2007.12.3
1115A081 BEARING,CONNROD PLAIN,STD 0
1115A082 BEARING,CONNROD PLAIN,STD 1
1115A083 BEARING,CONNROD PLAIN,STD 2
1115A084 BEARING,CONNROD PLAIN,STD 3
1115A085 BEARING,CONNROD PLAIN,STD 4

MANUF PERIOD 2008.01.1 -
1115A423 BEARING,CONNROD PLAIN,STD 0 RED
1115A424 BEARING,CONNROD PLAIN,STD 1 BLACK
1115A425 BEARING,CONNROD PLAIN,STD 2 COLOR LESS
1115A426 BEARING,CONNROD PLAIN,STD 3 GREEN
1115A427 BEARING,CONNROD PLAIN,STD 4 BLUE

------------------------------------------------

TAIHO Bearings Japan:
http://www.taihonet.co.jp/e/after_m01.html

G13B/4G15/G15B
MITSUBISHI MD143090 {ROD BEARINGS}
TAIHO SET NO = R130A (AFTER '88) / G13B  G15B
TAIHO PART NO = 64-130-1 [Unit Per Set 8]


How to Read Engine Details:
MODEL - YEAR
NOS. OF CYL X CYL CAPACITY BORE X STROKE
CAR NAME - MODEL

G13B - 1983
G4x1298CC - 71x82
LANCER -C11

4G15 - 1987-97
G4x1468CC 75.5x82
MIRAGE -C52,62,72
LANCER -C62,72

G15B - 1983
G4x1468CC 75.5x82
LANCER -C12,32

I also come across this:
MITSUBISHI MD030516 = TAIHO SET NO R119A / 4G11  4G13  4G15

MITSUBISHI MD147999 {MAIN BEARINGS}
TAIHO SET NO = M119A (AFTER '88) / 4G11  4G13  4G15
TAIHO PART NO = 63-119-1 [Unit Per Set 4]
                63-119-2 [Unit Per Set 4]
                63-119-(3)
 [Unit Per Set 2]

Stage 2 - Block Cleaning + Crank Install - 6hrs

More block cleaning, I'd estimate another 4hrs of rubbing down with thinners & ATF fluid. Then crank cleaning and installation.

Previous stage here: /stage-1-block-cleaning-4hrs.html
See the original strip down here: /le-klaw-bleu-forged-build-part-ii-4g15.html






Oil clearance @ Crank Shaft Mains
   0.020 − 0.040 [0.1]
 - looks like I have ~0.050mm, I could torque down the mains and bring it up?

Re-using old oil squirter, crank cleaning, the crank has been balanced up to 10k rpm (see more later).






Previous crank install:
/4g15-crank-installation-arp-main-studs.html
/big-end-oil-clearance-crank-endplay.html

WA Sprint Championship Round 1 - 8/3/2015 - Oyster Cove - 5.08km

WA Sprint Championship Round 1 - 8/3 - Oyster Cove - 5.08km - Shoot Out

Still running the same setup as last year, one of the few rounds before the new motor goes in!
Had some old CarboTech XP8 (or XP10) pads, stuck some new coil packs in, gearbox oil change, using my 3yr old Z221 & A050 combo (215/45 up front, 235/45 on the rear).

Car ran well, besides being too hot that the radiator guard started melting again. Not missing as much, but just getting back into it again.
















Using one of the only oils I can with a carbon ATS diff.
I might have to convert to braided boost lines.



















2nd in the class, and destroying lots of cars bigger.
167hp @ 1.5lt, can't wait to see if 300hp will help hit the top end of the scale.

Z27AG Shifter Repair - Another Shifter Linkage Broken

I broke my shifter linkage, but this time I came across a clients car with a broken linkage.

I didn't have much to recycle, compared to my setup in the past.








I tried a solid urethane insert - /solid-shifter-linkage-and-custom.html
The urethane lasted 2-3years, but it finally started popping off.







Then I made a ghetto bracket. /z27ag-shifter-linkage-repair-bracket.html
Then onto a solid shifter hiem joint /my-final-version-of-rcolt-shifter.html
 

Stage 1 - Block Cleaning - 4hrs

Total time: 4+hrs

According to my engine machinist, most engine failure happens because of cleanliness.

Funny you say that, as even though Adam's block was the cleanest in town.  Little did we know there was some swarf hiding somewhere deep inside. I have a gut feeling that this swarf had rusted and embedded itself somewhere that we couldn't clean /the-good-bad-forged-build-ii-under-knife.html 

Hence! this time i paid about $500 to remove all oil balls and tap with out for grub screws. This way I can inspect all galleries and at least flush the swarf out.

When cleaning a block, you might be confronted by flash rust. I believe this is from the debris from machining.  I think next time I will clean the block as much as possible before washing with water.  Use HOT soapy water.  Next time I might try a soluble rust inhibitor in the water as well.

Dry the engine block with compressed air and WD40, try and rub any flash rust off.  If you can't use some ATF fluid and let it soak

DO NOT I have removed the oil jets to stop rust and contamination during machining and cleaning.

/no-seconds-changes-md109259-oil-jet.html

I tap out every head stud and main stud as well.  Cleaning all threads multiple times. Spraying WD40 and compressed air through all the oil galleries.

Steering Components Refresh - Lower BallJoint Boot Replacement

Lower ball joint boots - I feel the top hole could be closer to 17/18mm and bottom hole closer to 32mm.

But overall the RB124K is a pretty good fit, I have been using it for a few years without issue.

Road Safe RB124K is the closest.
Top Hole Diameter  16 mm
Bottom Hole Diameter  34 mm
Height  28 mm

You can also see HR-6137 in the background.


















{another one that should be close to fitting}
RB18K
Top Hole Diameter  15 mm
Bottom Hole Diameter  34 mm
Height  30 mm







I have yet to measure the tie rod boot, it looks similar but, shorter.

So this car had another driveshaft put in, lower ball joint boots and sway bar linkages.
Its used in Honda's & Lancers, fit is ok, bushing are a bit smaller, but his ends were pretty rooted, otherwise I would have just put bushes on it, not worth the extra $50, it's not a performance upgrade by any means. /4sale-swaybar-linkage-bushes.html



Front Sway Bar Endlinks, Type R sway bar, Civic EG 92-95, Integra DC2 94-01 (see also HR6480)
Hardrace front sway bar end links for EG DC2 with Type R front sway bar
Part Number: HR-6137

Blox Front Sway Bar Fixed End Link Set DC Integra EG Civic -
these fixed end links for front sway bar specifically for the 92-95 Civic / 92-97 Delsol / 94-01 Integra that's utilizing a 24mm GSR or Integra-R front swaybar.
Applications:
92-95 Civic using a 94-01 GSR or Integra-R 24mm front sway bar
92-97 Delsol using a 94-01 GSR or Integra-R 24mm front sway bar
94-01 Integra GSR / 97-01 ITR
Part Number:  BXSS-10106