2004 STi Twin Scroll 6262 by Layvon

10 minute(s) of a 190 minute read

The final goodies have arrived!

10/13/2012

Got to drive today! First time since January 29th she's left the garage!

10/21/2012

Gah! I'm getting stressed out. Between working 60+ hrs a week and middle of November only two weekends away I'm getting nervous. 

Found a leak tonight under the throttle body, which means I have to take my FMIC pipes and alternator out to get in there.. thankfully Dom made me look into my MAP low voltage code, cause that thing was leaking like a sieve. I hope I didn't overlook a channel or something in the throttle body when I rotated it. I don't have much time to spare any more.

Things yet to do -

Find boost leak, address, and fix

Figure out which 02 sensor I have is bad.

Drive 900 miles

Yank motor

Tighten head studs

Confirm valve lash is correct

install motor

Test drive to verify nothing else went.

Debating on installing my computer here or down in Chicago... but that can go on the list too.

10/27/2012

I'm about to say **** it.

For some reason, from the throttle body back wont hold any air now. I tested from the Throttle body going towards the turbo and was able to hold 5psi back with my hand, so that eliminates big huge gaping hole there. From the throttle body though it just sounds like air is just rushing though, yet I cannot find a hole that is making any noise. the little ****ing aircompressor that i have kicks on every 45 god damn seconds so as soon as you can make any progress that sonofabiutch kicks on.

Stupid question, but if the engine shut off just right could that affect why it wouldnt hold air? I apparently dont know **** about these motors, cause Im so fed up with chasing these gremlins. Pressure is ****ing on too to try to make it to Chicago in 3 weeks otherwise i'm going to look like a fool when i get down there. 

Got my Alternator remount bracket and that installed fine also. Used the new bracket and an old timing belt pulley to make a tensioner in conjunction with the outfront bracket.

https://docs.google.com/open?id=0B79...Ww0cXYxaTJ0Mmc

Anyone willing to look at logs for some help would be much appreciated...

11/6/2012

Well glad I took the time to check.. valve lashes were less than perfect. 

According to the documentation I have from Cosworth my cams should be .008 +-.001 and. 010 +- .001 for intake / exhaust respectively. Can anyone confirm for the 278/274 cams?

I took good notes and will be tightening head studs tomorrow, hopefully I can mix and match with what is on my car and the 15 extra buckets I have to make it work. Otherwise Jamie at SGP is getting a call!

11/9/2012

Got everything buttoned back up tonight. Got buckets from Angel down in detroit, and everything measured up right at .008 or .007 for intake, and .010 or .009 for exhaust. 

Put roughly 15 psi worth of springs in the wastegates too, hopefully a good level for 22-25 psi with boost control.

Head studs are torqued to 98.6 ft pounds a piece, for a little added assurance.

First positive night I've had in the garage in a while. Hoping I can get a hold of Dominic tomorrow to get my base map, because with some luck, I'll have my car fired up again tomorrow afternoon and driving sunday would be nice. Dyno Thursday and only have 135 miles on motor

11/11/2012

Everything went well today! Took a little longer than expected but that's okay. Pressure tested to 25psi and everything held tight. Fired up and idles about the same as it did. Will start and idle fine till you hit the throttle then it bogs down and dies. 

Have to blip the throttle to get it to turn on too..

11/15/2012

Well.. Shes running well. MAP error was taken care of by Dom, nothing major or leak based, just minimum voltage. 200 miles down. 800 to go.

Hitting roughly 10-12 psi for break in boost. Hit 15 once... that was a tempting oops. Kinda like having sex the first time without a condom. You know you shouldn't but it just feels so good!

11/15/2012

Meant to post this too

I haven't had the camera out much lately. . . but I should here soon. Here is what I do have from my cell phone. Once I get done on the dyno, I plan on making things look a little prettier. If I wait long enough for the dyno, the Tee fitting that people are going to say is a problem will become a Y. If I wait a really long time, I'll run both to the FPR. I'm just tired of spending money right now

To anybody curious about the knock block questions I was asking, Simon from link said that if I hooked it up to the stock knock wire, it'd work great. since it is only a one wire knock sensor he said that you don't need to hook the negative side of the knock block up to anything. I plan on using one of the TGV auxiliary ports, and DI 6, which was one of the cruise control inputs. as long as I don't cut the wrong wire, it shouldn't be too hard to wire that in.

I think that I will be hooking up oil pressure to the another TGV input AN4 or 5, I'm in the process of tinkering with my map that I've "made" seeing what link can do. I think we all know that Bariga voices his opinion, but I do think I have to side with him on this software structure. everything is so intuitive it makes me feel dangerous.

Levon

12/2/2012

Still no Dice.

AFRs are all over the place as soon as the computer switches over to the 02 sensors vs the map. Idles rock solid for the first 15-25 seconds I turn it on, then it goes back and forth from 12.5 - 17.7. This map previously had no problems, thats why I'm thinking it is a mechanical failure of sort vs the ECU / Sensor aspect. I was hoping for a vacuum line being off.. Didn't get that lucky.

What I've tried to do to diagnose:

1) tighten all fuel fittings, none were loose as a goose, so that wasn't it.

2) vacuum tested to 15psi. Everything checked out. No gaping holes Like I hoped there was.

3) disconnected the lines going from the Turbo nipple to the boost control solenoid and capped it to see if the leak was from that side of the

4) verified that the bov isn't leaking.

5) checked how much vacuum it is pulling. Appears to be similar to before before the sensors turn on

12/8/2012

This is about to be somebody else's problem

I found a fuel leak again. Same place on the same injector as before one drip about every 2-3 seconds. Thankfully I had extra orings and the other jazz to fix it this time. I was all giddy getting ready to start it up and then the same problem happened. 

Idles fine until the sensors get warmed up then all over the place. ... 

Do I dare say a bad sensor? These sensors are appx 6 weeks old, and haven't been banged around at all.

PLEASE if anyone has any ideas let me know.

12/11/2012

I dont have any more fuel leaks. Maybe I didn't update that concisely, but I fixed the leak I did have on Saturday. 

Latencies / Scalars are believed to be correct. When the car first starts up, it is running on what is stored in the computer while the sensors warm up. Once my fuel trims start being adjusted based on the O2 readings is when it starts messing up. 

I did not think to check PCV valve, Maybe I will yank that off and see if it shakes around. When I was doing a boost leak test I did hear air coming through that tube going to the Air Oil Separator. . maybe its opened up.

There is no exhaust leaks. I checked that Saturday when I was under the car. 

I am on the OE computer. Once I find this issue, I'm going to drive 100-200 more miles and start swapping in the Link. Barometric has been confirmed. I haven't logged the MAF for temp, but I probably should / could. 

Thank you for the very helpful post, I definitely have some more things to take a look at. 

Manitou - I did do another boost leak test, but I think I overlooked the PCV, at least looking at it.

12/26/2012

Well, a few of you now know, but I replaced the sensor yesterday and it idles much better. Let it sit and idle for 20 min before making this post, and AFRs stayed between 14.0 and 15.5 for the most part. I have to put the fender liner back in and zip tie that into place. (04 Liner with 06 Fender / bumper aka being cheap). 

If the snow gives me an opportunity to do so, I'm going to take it for another 100 miles or so and call it good.

Junior has been contacted to get this bitch done.

1/7/2013

Bits of exciting news today. Some relating to this thread, one doesn't

1 - I'm paying my car off Friday! Between xmas bonus / savings / yearly vehicle "stimulus" from work, I have enough to pay it off. Figure it would be the smart thing to do with my money. $14 in student loans and debt free. Could be debt free if I wouldn't have built a motor, but what is the friggen fun in that.

2 - I drove my car 50 miles yesterday, first time since i put the new O2 in. I talked with Manitou last night and was ecstatic to tell him, 14.7 AFR for 10-15 seconds driving down the road, was tickled pink. ... Ohhh.... Juniorrrrr please put down the GT-R for a few days please

3 - My girlfriend just got a job offer that will allow her to live with me so we can save money and live together. 

4 - My grandma had a petscan today and 4 / 5 cancer spots are gone, this is a huge deal! her 3rd bout with breast cancer.

At last, I feel like 2013 has started out to be a great year so far. Knock on wood

5 - Did I mention I drove my car yesterday??