Stage 4 - Big Ends, Pistons and Rods - 6hrs

Previous Build Sheet - 1mm oversized bore-->
After double checking ring gaps and cleaning the bores another couple of times, it was time to get serious and finish the bottom end.

I also had to figure out the big end clearance.

This is a sheet I created when I did the first build.
I have yet to complete a sheet for this current build

Using .0055" of stretch I am running about .038-.05mm of oil clearance on the big end.
I will slightly increase the stretch to ~.0065"

I wanted to compare the three torque wrenches with a stretch gauge.  Interesting enough, they do vary by about 5ftlb.  After receiving some information from a professional engine builder I went on the path of testing the torque wrenches.

I was using the ARP chasing the stretch method, but I decided to try the below method.

http://www.performanceenginetech.com/connecting-rod-bolts-stretch-vs-torque/

"Depends on the type of fastener you are using. Word of advice though, when doing it by stretch, zero your stretch gauge on the bolt, remove the stretch gauge and then tighten the bolt to tension and angle and check the stretch. I usually start off at the lower torque spec and move my way up to get the desired stretch. On a 7/16 A1 rod bolt I aim for 0.0053-0.0057, providing your bolt yields the same, that will be spot on.

Don't place the stretch gauge on and tighten at the same time, this is what you'd call chasing the stretch and will always have inconsistent results"

I preloaded the opposing bolt to ~20ftlb and the zero'd the stretch gauge and torqued from
43->50->55ftlb to work out the desired torque for the given stretch of ~.0055"

Fuel System Design - Turbosmart - FPR 1200 -6 AN

The Injectors & Pump:

/e85-plans-fuel-pump-injectors.html
Fuel Filter:
/mr526974-filter-assy-fuel-tank.html
AN Fittings (more to come):
/oil-cooler-stainless-fuel-lines.html





Fuel Reg:
1 x TS-0401-1003 - Turbosmart - FPR 1200 -6 AN
1 x TS-0402-1111 - FPR Fitting Kit -6AN to -6AN








Flex Fuel (Zeitronix E-85 Flow Through Flex Fuel Sensor):
2 x AF808-02 - Push-On EFI Fuel Fitting 3/8" Hose Pressure Side - 3/8",-6AN





Hose Ends:
AF201-06D - 200 / 570 Series PTFE Straight Hose End -6AN
AF203-06D - 200 Series PTFE 90° Hose End -6AN
AF204-06D - 200 Series PTFE 120° Hose End -6AN







OEM Stock Fuel Rail:
1 x AF808-01 - Push-On EFI Fuel Fitting 5/16" Return Side - 5/16",-6AN
1 x AF803-01 - 90° Push-On EFI Fuel Fitting 5/16" return side to -6AN, Blue - 5/16",-6AN
1 x AF816-06-02 - Male Flare -6AN to 1/8 NPT
W-FRB-E4 / W-FRR-BS Fuel Regulator Bracket Set (small) – Mit new GSR/4G91/92/93, Toyota, Nissan

Fuel rail adapter to fuel reg.
/love-juice-phase-i-fpr-1200-zeitronix-e.html
/fuel-pump-install-z27ag.html

WA Sprint Championship - Overall Results - Round 3 - 17 May 2015 - Course: The Sideling - 4.95km

Enduro mode - all 3 laps account for your score

2015 WA Sprint Championship
Overall Results - Round 3 - 17 May 2015
Course: The Sideling - 4.95km

Ahhh...One off lap, one lap with zero visibility, one okay lap.
First time racing with standing water, scary stuff.
Came off the track quicker than I could shit my pants.

Colt is covered in grass and dirt :(
Previous outing ->
/wa-sprint-championship-overall-results.html

MR526974 - FILTER ASSY, FUEL TANK - Ryco Z653

Looking to trouble shoot some fuelling issues, going to start with a new sock and filter.

/fuel-pump-install-z27ag.html

# Number Description Qty.
05014 MR599502 HOSE, FUEL FILLER. Period: 2006.05.1-...; 01
05015 MR599503 HOSE, FUEL FILLER NECK BREATHER.
                Period: 2006.05.1-...; 01
05076B MN120146 CLIP, FUEL FILLER PIPE.
                Period: 2006.05.1-...; Part Spec: 36.5; Size: 36.5 02
05076C MS660168         CLIP, ROCKER COVER.
                Period: 2006.05.1-...; Part Spec: D=17.8; Size: D=17.8 02
05100 MR970488 FUEL TANK. Period: 2006.05.1-...; 01
05140A 1760A195         PUMP & GAUGE ASSY, FUEL TANK. Period: 2006.05.1-...; 01
05145B MN106247 GAUGE UNIT, FUEL TANK. Period: 2006.05.1-...; 01
05149 1760A275         PUMP, FUEL TANK. Period: 2007.07.1-2007.06.3; 01
05171 1706A022         PROTECTOR, FUEL TANK, LWR. Period: 2006.05.1-...; 01
05175 MB052997 STOPPER, FUEL TANK PROTECTOR. Period: 2006.05.1-...; 02
05210A MR526974 FILTER ASSY, FUEL TANK. Period: 2006.05.1-...; 01
05213 MN163114 CUSHION, FUEL TANK PUMP. Period: 2006.05.1-...; 01
05261 MN106046 GASKET, FUEL TANK PUMP. Period: 2006.05.1-...; 01
05265B MR970494 HOSE, FUEL TANK. Period: 2006.05.1-...; 01
05265E MN139782 HOSE, FUEL TANK. Period: 2006.05.1-...; 01
05287 MR529146 O-RING, FUEL TANK. Period: 2006.05.1-...; 01
05288 MR529140 GROMMET, FUEL TANK. Period: 2006.05.1-...; 01
05289B MS440501         NUT, FUEL TANK.
                Period: 2006.05.1-...; Part Spec: WASHER ASSEMBLED,5; Shape: WASHER ASSEMBLED; Size: 5 06
05289C MS440504         NUT, ENG MOUNTING.
                Period: 2006.05.1-...; Part Spec: WASHER ASSEMBLED,10; Remarks: COLORED; Shape: WASHER ASSEMBLED; Size: 10 04
05291B MS660169         CLIP, FUEL TANK.
                Period: 2006.05.1-...; Part Spec: D=10; Size: D=10 02
05291BB MN106252 CLIP, FUEL TANK.
                Period: 2006.05.1-...; Part Spec: 8; Size: 8 03
05291BB MN106253 CLIP, FUEL TANK.
                Period: 2006.05.1-...; Part Spec: 10; Remarks: GRAY; Size: 10 02
05291C MB908114 CLIP, FUEL TANK. Period: 2006.05.1-...; 01
05291E MN139479 CLIP, FUEL TANK. Period: 2006.05.1-...; 02
05296 MS240121         BOLT, FUEL LINE.
                Period: 2006.05.1-...; Part Spec: WASHER ASSEMBLED,6X16; Shape: WASHER ASSEMBLED; Size: 6X16 04
05412 MR970491 HOSE, FUEL HIGH PRESSURE. Period: 2006.05.1-...; 01
05501 MR529134 BRACKET, FUEL PUMP. Period: 2006.05.1-...; 01
05501B 1760A218         BRACKET, FUEL PUMP. Period: 2006.05.1-...; 01
05583B MR529143 CAP, FUEL PUMP. Period: 2006.05.1-...; 01
05586 MR271158 PLATE, FUEL PUMP BRACKET. Period: 2006.05.1-...; 01
83023 MR529141 HARNESS, FUEL PUMP. Period: 2006.05.1-...; 01







Fuel assembly, fuel pump sock, etc.






MITSUBISHI      MR526974
ALCO FILTER FF-052
BECK/ARNLEY 043-3009
AMC Filter MF-4678
ALCO (ZYPERN) FF052
JS-FILTER       JN6500 / JS6500
SAKURA          FS1031
RYCO Z653




Suits Pajero:   > 08.00~09.06 3000 6G72     V63W
                       > 08.00~09.06 3000 6G72     V73W

Housing Info:
   HT: 152mm
   OD: 92mm
                  OEM fuel tank baffle ------>
OEM Pump (unconfirmed dimensions):
Pump Diameter 38mm
Overall Length 111mm
(Goss P# GE043)

** I believe the Australian Pajero V63W/V73W uses an external filter,
hence the part numbers are different.

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

From Ryco - They Quote a Z885, which they list is for the below Pajero
this is a different Pajero model from my previous data.

Z885
RYCO FUEL FILTER
> MITSUBISHI Pajero (NS, NT & NW)

I believe NS, NT & NW = V97W, 3828cc, 6G75 V6 24v SOHC

Which quotes:
Pump Diameter 38mm
Overall Length 111mm
(Goss P# GE044)




Z885 is the wrong listed number, RYCO Z653 is the correct number.
















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

Walbro GSS342 (unconfirmed dimensions):
Fittings In (mm):- 8
Fittings Out (mm):- 11
Voltage - 12v
Flow Ltr/Hr (Max):- 318
Flow Ltr/Hr @ 3 Bar (44psi):- 255
Flow Ltr/Hr @ 5 Bar (73psi):- 225
Max Pressure:- 8.5 Bar
Length (mm):- 120
Diameter (mm):- 39.2
Weight (Kg):- 0.366








Modifications i made to fit the fuel pump, from cutting up the rubber mount to grinding the tabs/feet off the fuel pump

Searching for Valve and Springs - Custom Order - RColt - No Direct Fit

OEM Numbers - From Manual and some I measured (not that accurate):
Head diam (measured)
I = 30mm
E = 25mm

Length (manual specification)
I = 106.35mm
E = 106.85mm

Stem diameter (measured)
5.46mm


Margin (manual specification)
I= 1mm
E=1.5mm

Seat (hard to measure)
I = 3.6mm
E= 2.2mm

Tip length
4.5mm

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

[I measured OEM springs VS after market springs]
Coil Binds
OEM........... 120lb @ 1.145" = 29.08mm
Aftermarket... 140lb @ 0.960" = 24.38mm

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

--------------------- Close but no cigar - Valve Options -----------------------

Option 1 - Springs
Will Fit 2011+ Honda CR-Z 1.5L LEA Hybrid Engines:

SPR-H2416 - Springs - 61lbs @ 40.2mm
RET-H2416 - Retainers

Part Number: SPR-H2416
Type: Single Spring
Press.Seat: 61 @ 40.2
Press.Open: 164 @10
Max Lift: 15.3
Coil Bind: 24.90mm
Rate: 9.90
OutSpr.OD: 23.70mm
OutSpr.ID: 16.30mm
InnSpr.OD: Single

/le-klaw-bleu-forged-build-part-i-4g15.html

Option 2 - Exhaust Valves
Part No = 11367-8
HONDA CIVIC 1.6L -
SOHC 16 VALVE ( D16Z6-Y5-Y7-Y8 )

Type Exhaust
Head Diameter 26.0 mm
Stem Diameter 5.46 mm / .2150″
O/A Length 115.95 mm
Tip Length 1.9 mm
Underhead Angle/Radius 25° x 11/32″
Margin .065″
Seat Width .080″
Top of Head 20° Dish

{there is a 27mm option valve therefore +2mm}

Option 3 - Intake Valves
Part No = 11131-8
2001-Up Acura RSX Type S 2.0L - DOHC I-VTEC 16 Valve (K20A2)

Type Exhaust
Head Diameter 31.0 mm
Stem Diameter 5.46 mm / .2150″
O/A Length 109.04 mm
Tip Length 2.08 mm
Underhead Angle/Radius 25° x 11/32″
Margin .065″
Seat Width .080″
Top of Head 20° Dish

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

More Info

HONDA CR-Z 1.5L LEA 4Cyl 16v
Part Number: SPR-H2416
Type: Single Spring
Press.Seat: 61 @ 40.2
Press.Open: 164 @10
Max Lift: 15.3
Coil Bind: 24.90mm
Rate: 9.90
Retainer: RET-H2416 + SEAT-A2416-IN + SEAT-A2416-EX
Details:
View More
OutSpr.OD: 23.70mm
OutSpr.ID: 16.30mm

Option 4 - Exhaust Valves
HONDA CIVIC (1992 - 2000) EXHAUST, STOCK 5000 SERIES HI PERFORMANCE VALVES
1.6L - SOHC 16 VALVE (D16Z6 - Y5 - Y7 - Y8)
Exhaust

Head Diameter: 26 mm
Stem Diameter: 5.46 mm
Overall Length: 115.95 mm
Tip Length: 1.9 mm

Option 5 - Exhaust Valves
HONDA CIVIC (1992 - 2000) EXHAUST, STOCK 6000 SERIES COMPETITION VALVES
1.6L - SOHC 16 Valve (D16Z6 - Y5 - Y7 - Y8)
Exhaust
Head Diameter: 26 mm
Stem Diameter: 5.46 mm
Overall Length: 115.95 mm
Tip Length: 1.9 mm

Option 6 - Exhaust Valves
HONDA CIVIC (1992 - 2000) EXHAUST, STOCK COMPETITION PLUS ENGINE VALVES
1.6L - SOHC 16 Valve (D16Z6-Y5-Y7-Y8)
Exhaust
Head Diameter: 26 mm
Stem Diameter: 5.46 mm
Overall Length: 115.95 mm
Tip Length: 1.9 mm
Reference: 22" Flo. Stock size. Super Alloy

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

Option 7 - Intake Valves
HONDA CIVIC (1992 - 2000) INTAKE, 1MM OVERSIZE 5000 SERIES HI PERFORMANCE VALVES
1.6L - SOHC 16 VALVE (D16Z6 - Y5 - Y7 - Y8)
Intake
Head Diameter: 31 mm
Stem Diameter: 5.48 mm
Overall Length: 118.6 mm
Tip Length: 1.9 mm

Option 6 - Intake Valves
HONDA PRELUDE (1993 - 2000) EXHAUST, 1MM OVERSIZE 5000 SERIES HI PERFORMANCE VALVES
2.2L - DOHC V-Tec 16 VALVE (H22A1 - A4)
Exhaust
Head Diameter: 31 mm
Stem Diameter: 5.48 mm
Overall Length: 107.1 mm
Tip Length: 2.5 mm
Reference: 22" Flo. + 1 mm oversize. Flat Head. Special Alloy

Option 9 - Intake Valves
HONDA CIVIC (1992 - 2000) INTAKE, 1MM OVERSIZE COMPETITION PLUS ENGINE VALVES
1.6L - SOHC 16 Valve (D16Z6 - Y5 - Y7 - Y8)
Intake
Head Diameter: 31 mm
Stem Diameter: 5.48 mm
Overall Length: 118.6 mm
Tip Length: 1.9 mm

WA Sprint Championship - Overall Results - Round 2 - 12/4/2015 - Course: Targa West - 4.40km

WA Sprint Championship - Overall Results - Round 2 - 12/4/2015 - Course: Targa West - 4.40km

Ahhhh - Car went like sh!t first lap, zero throttle response for parts of the track :(
Lap 2 and 3 was a right off.  Spun off on third lap (backed off the throttle in a wet patch).
Second lap the rear wheel nuts came loose. I think I forgot to torque it.
From now on I will re-torque the wheels when they are hot.



Previous Event (Round 1) -
/wa-sprint-championship-round-1-832015.html
Another Event I dug up years ago - /mcmotorsports-track-day-endurance.html

As far as results go, my quickest lap...I was higher ranked than expected 27/71 compared to last time.
40/84.
Maybe lest big dogs were out.







Ran the 215/45 on the rear (7.5") and 225/45 up front (8.5")














Trying to keep the place tidy, its getting annoying removing and installing tires all the time.