Giving a 405 Sport Wagon another chance

6 minute(s) of a 111 minute read

Last Saturday I replaced the gas tank and filler neck do to leak and holding fuel nozzle while fuling was driving me crazy. All good now no fuel leaks and fuel nozzle is not clicking off any more.

I also repaired speedo cable and replace idle control valve. Wagon and Sedan gas tank and filler neck are the same.

8-28-2014

Grrrrr this sucks big fat D... It looks like it may have head gasket issues,it pushes coolant through over flow weep hole on the hot day when it's not running. To top that off there was some construction work on I 80 and one of the debris cracked my windshield :-(

This 405 had a factory option of VIN numbers being engraved on all of the windows so I'm very mad that will go away.
However I did file claim with Caltrans so we shell see what will happened.

9-9-2014

Well it looks like I had faulty new radiator cap. I did CO2 test in cooling system and it passed,so I replaced thermostat,radiator cap and after that I had no problems.

I also did oil change,Mobil 1 was on sale.

9-10-2014

Lifters are noisy on this engine so that's on the list to do as well, I ran sea foam and it made it better but after 3000RPM they are really noisy.

9-15-2014

Radiator was seeping since day one so that got replace today with out removing intake manifold :-) also I replace leaking intank fuel pump housing.

10-18-2014

Last few weeks ago I've noticed really bad oil consumption however engine was running good and strong. Today on my way to work check engine light came on and engine was cutting out,right after that started to make a lot if noise. At that point I knew it was engine failure so I kept driving few yards longer just to get off the Freeway. Long story short this wagon has engine block inspection hole.

I think that rings gave out,perhaps one or two broke which caused high oil consumption,I new it was a ticking bomb waiting to go off :-(

Your engine failure sounds just like mine did :-)

I got spare engines but unfortunately for me it will be a while before she back on the road. MI16 now needs to be done ASAP and DSM needs some love as well.

I'm thinking to have head rebuilded,change piston rings,main and rod bearings.

10-31-2014

Engine is at machine shop and tomorrow I'll pull out one with the inspection hole.

I will have my friend (DSMer) Franky to help out. Bring out Monsters and Pizza :-)

11-3-2014

I sure know how to destroy them.

11-9-2014

Spare engine is at machine shop. I should have some news by friday. 

I told them to go ahead and just built the head with out calling me,I gave them new valve guides and stem seals.

11-13-2014

I found head bolts at Spoox Motorsports and I also got coming Tming Belt 

Water Pump 

Short Shift Rods

Inner Axle Boot 

Outer Axle Boot 

P/S Belt 

Dip Stick 

Short Heater Hose 

Right Motor Mount 

Outer Tie Rod End.

Now I'm regretting for not getting K24 on Ebay with all accessories:-(

11-19-2014

Cylinder head is finished with the machine shop no news on bottom end. I also ordered 1g DSM engine roll stop Urethane mount.

11-20-2014

Moooo parts :-)
Lower control arm bushings,ball joints,sway bar bushings and links installed.

11-23-2014

1g DSM roll stop fits much better.

Thanks to Spoox motorsport head bolts came in.

11-25-2014

I end up ordering XU10J4RS AKA 306 GTI-6 engine and 6 speed transmission from UK.

I'm very excited about it :-)

12-9-2014

Installed camber plates today.

I also intalled tie rod ends and engine mount. I'm still patiently waiting for that engine.

12-22-2014

Three weeks after payment was submitted and engine has not been shipped yet :-(

Both of us are waiting patiently!

12-31-2014

While back I found picture of 405 Wagon with modified MI16 rear bumper,I'm trying to duplicate same results. A lot of trimming will be necessary and some type of mounting brackets will need to be made.

This is how far did I got.