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

MBK-8015HD - 215mm Mitsubishi - Clutch Install, Yet Another

I am not shy of a clutch change, its a long job but fairly straight forward.
The HD Exedy that is sold is basically the same OEM clutch with an upgraded pressure plate.
I should have looked more closely, but I didn't. It uses the same clutch disc.






Which I thought was strange considering the money you pay.
/z27ag-ralliart-colt-clutch-install.html
/z27ag-clutch-and-rear-main-pii.html







A must read: 
/removing-gearbox-installation-tips-for.html
and for the true passionate home mechanic: 
/disassemble-fitment-of-z27ag-gearbox.html



























/over-fill-kit-installation-gearbox-oil.html

What it takes to make a 9second All Motor Civic - Years & $$$

Met this guy through the love of cars, he is also a home DIY pro. Self taught himself everything because shops couldn't be trusted.

Years later, he is just about done on the build.

I only caught glimpses of it in its final days. If only I could have seen it progress.

New Coils - Why Not Use the Toyota Echo Ones :)

Okay. After having some spark blow out issues, I decided its time to address the coil packs.
The old coil packs, meh. So yeh. Here we are, after two weeks and a couple hundred dollars I ended up with some Echo coil packs made by Denso. I got the coil packs then it was trying to find the loom. Pain in the bum, but its done.






The idea came from the Evo boys, they have been using the Echo coil packs for awhile.









Yellow, IGF isn't need.
12V, GND & Trigger



















I had to modified the nose and muck around with the spring to make it work. The brass bushing also needed to be modified.



















Manufacturer Part Number: 90919-02240
Part Number: UF-316
Brand: Denso
Other Part Number: C1304
Part Brand: TOYOTA GENUINE (DENSO)















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

OEM Details 

 #Number Description Qty.
MN119739 COIL, IGNITION. Period: 2006.05.1
1822A005 SPARK PLUG. Period: 2006.05.1-...; Part Spec: ILZFR6C-K; Standard: ILZFR6C-K
-----------------------------------------------------------------------

00-05 Toyota Echo Ignition Coil Packs Denso 90919-02240 Prius Yaris Scion 1.5l
These will work on any 00-05 Toyota Echo with the 1NZ-FE 4-cyl engine as well as many Scion X-series

Toyota / Scion OE Ignition Coil
Scion xA, xB 2004-06
Toyota Echo 2000-05
Prius 2001-09
Prius C 2012-14
Yaris 2004-14

Toyota 90919-02240 (Denso 673-1306)
Max Usable Dwell: 3ms
Dwell: 2ms/3ms
Primary Current: 6.5a/11a
Spark Energy: ~47mJ/~52mJ

LS2 Coils
Max Usable Dwell (MUD): 5ms
Primary Current @ MUD: 11a
Spark Energy: ~120mJ

/research-into-colder-plugs-z27ag.html
I decided to go with warmer after trying IKH22, I stepped down to IKH20.

http://s-86.com/article_coilpacks.php
Coil 1: 90919-02227 ST215 Caldina 3SGTE
Coil 2: 90919-02230 GXE10 Altezza AS200/Lexus IS200 1GFE vvt-i
Coil 3: 90919-02239 ZZE120 Corolla 1ZZFE
Coil 4: 90919-02240 NZE121 Corolla 1NZFE
Coil 5: 90919-02236 SXE10 Altezza RS200 3SGE Beams dual vvt-i

Another little item I plan to add, if I still have issues. Planning to run shielded wire with a new loom soon.  No short-cuts this time.
BWD G120P - Ignition Condenser

Another option:
Bosch Motorsports and are the P100-T coils