Jan 14th 2008 - Tonight was a busy night... I was determined to work my ass off and get as much done on the van before I burned out and needed to get some sl... Show moreeep.
Check list includes :
-Making my own adjustable wastegate arm. (Ghetto, but it works)
-Re-installing head on the block (Harder to re-install then remove when by yourself)
-Torqued head to specs
-Attached fuel lines
-Re-mounted timing gear (with retained timing)
-Attached vacuum lines
-Attached electrical connectors
-Re-attached wiring harness to firewall bulkhead (Pain in the ass)
-Installed plugs and wires
-Installed lower intercooler hose
-Installed turbo inlet hose
-Mock-fitted Intercooler to pipe to check clearances
After 6 hours of working in the garage, Im exhausted.. More tomorrow.
Jan 13th 2008 - Mock-up of gauge pod. Still unsure what im doing with this. ( AUTOMETER; Boost, Tranny temp, and Pyrometer gauge )
Aswell as my Turbo Action RMVB
January 10th 2008: As of tonight the head is fully finished and ready for re-installation. Also the Intercooler is re-painted and ready for installation aswell.
Check page 3 for racing bet made with best friend!
As of January 8th 2008: I installed the 20 injectors, installed the intake, and exhaust manifold and installed the garrett onto the manifold. The head is almost ready to be re-installed in the van. All thats left to do now is run the coolant lines and it'll be ready to go!
As of December 27th 2007: Cylinder head is off!
I removed the cylinder head / intake manifold / exhaust manifold / turbo / fuel rail, as a complete unit. It weighed close to 100 pounds easily, and quite awkward. Many people advised against removing it by yourself, but you can do it if you've got a bit of muscle. IMO.
Once it was on the bench, I removed the turbo, then exhaust manifold, then the intake. A few of the bolts were in a real PITA spot, requiring you to remove the parts in that order to access the last few bolts. I didn't take pictures because I was having too much fun tearing it apart. = )
Next on the list is cleaning the gasket surfaces, painting the valve cover and intake manifold again, installing the 20's, installing the manifolds and the Garrett turbo. Then its just a matter of re-installing the head and putting all the pieces back together. I'll keep updating as I can.
Although it may look like #2 and #3 cylinder has issues with the crap in the cylinder, its just debris from the head removal, I simply need to vacuum it out.
Update : All gasket surfaces on turbo, intake, exhaust and cylinder head have been cleaned and are ready for re-assembly. Show Less
Unfortunately the van has common rust issues in the passenger side rear wheel well and rocker. So I purchased a new rocker and quarter panel to install this ... Show morewinter. The bright side is that it saw very little winter driving, so the rest of the van is amazing for a 18 year old ontario vehicle.
I have a few goodies on the bench that are going to be installed on it over this winter.
- A freshly rebuilt Garrett T3, converted to TII specs.
- A Forward Motion ported stock exhaust manifold. (Flows 28% better then stock)
- A 2.5inch swingvalve for the Garrett, to replace the 2.25 inch stock one it came with.
- A T2 intercooler with piping
- Cone air filter
- A Eagle Talon blow off valve (To replace my plastic stocker)
- A oversized tranny cooler from a Ram Van. (Almost twice the size of my stocker)
- A Reverse Manual Valvebody for my a-413 transmission. Giving me full control over the 3-speed auto, aswell as super hard shifts.
!NEW! Update: November 21st 2007
Installed Pumper rims (Thanks Ben), and installed replica "turbo" decals.
Turbine housing before and after
.. and the famous non-gasketed turbo flange
Turbo Rebuilt Show Less