2004 Lancer Sportback TURBO Ralliart

June 29, 2013...












Finally finished, but elected to wait till after Monday to send out for ceramic coat so clearance for the WG actuator bracket can be mocked up on Monday. The actuator is NOT being mounted as previously described (imagine that), but rather directly below the actuator lever, in front of the oil pan, which positions it right next to the downpipe, hence the ceramic coat to keep from frying it.

The steel, male bung for the oil pan return is on order from Michigan

 

June 30, 2013...

I asked hackish, "one step colder," was his reply, and found a pretty informative article on the same:

" Do I need a colder spark plugs? A rule of thumb is one heat range colder for every 75–100hp you increase. In identical spark plug types, the difference from one full heat range to the next is the ability to remove 70°C to 100°C from the combustion chamber. The heat range numbers used by spark plug manufacturers are not universal, so a 10 heat range in Champion is not the same as a 10 heat range in NGK or in Autolite. When making the decision to change the heat range of your plugs, it is a wise idea to make changes in 1 heat range increments, checking all your plugs for suitability during your test. Vehicle modifications during the test phase of your plugs is not recommended as this may skew your results."

Gap: Gap has a lot to do with igniteability. The bigger the gap, the better combustion. HOWEVER, this comes at a cost. The bigger gap requires MORE voltage to spark, puting a much higher strain on your ignition system. With a turbo charged motor, the gap is usually smaller. This is due to the fact that higher cylinder pressures make it harder for the plug to fire, therby increasing voltage requirments (this is why 2.5L NA is 0.044" gap and the 2.5L turbo is 0.030" gap). Can your ignition system handle the increased load?? Good question." - http://forums.nasioc.com/forums/showthread.php?t=518633

 

NGK 2309 LFR7AIX Single Iridium Spark Plug Specifications:

Thread Size: 14mm

Hex Size: 5/8" (16mm)

Reach: 26.5mm (1.04")

Seat Type: Gasket

Gap: .032" (0.8mm) I

Heat Range: 7

Terminal Type: Solid

Resistor: Yes

Thread Pitch: 1.25mm

Brand: NGK

Center Electrode

Type: Fine Wire

Material: Iridium

Size: 0.6mm

Projection: Projected

Ground Electrode

Type: Taper Cut

Material: Nickel

Quantity: 1


OEM NGK 3656 LZFR6AI Iridium/Platinum Spark Plug Specifications:

Thread Size: 14mm

Hex Size: 5/8" (16mm)

Reach: 26.5mm (1.04")

Seat Type: Gasket

Gap: .032" (0.8mm)

Heat Range: 6

Terminal Type: Solid

Resistor: Yes

Thread Pitch: 1.25mm

Brand: NGK

Center Electrode

Type: Fine Wire

Material: Iridium

Projection: Extended Projection

Ground Electrode

Type: Standard

Material: Platinum

Quantity: 1

 

July 08, 2013,..

From an un-named reliable source:

"I always drive my car slowly into my neighbourhood. This is sufficient to cool the turbo down even if I have driven the car hard immediately before. I do not have a turbo timer on any of my cars and have never cooked my bearings."



More gifts arrived today therefore more progress at the shop:










Lastly, showing that the intake pipe slides easily under the transmission lines and over the lower radiator hose:

 

Not a pretty day, but the shop was open nonetheless:

 

Oil Pan Bung & Return Line...

 

Recirc valve clocked to the underdide of the UICP...



Manifold gaskets in place with chrome acorn nuts and washers with starter heat shield/wrap:

 

@ the muffler shop, 0825 Friday July 19...

 

Towed back to the house, July 22, 2013...

Got the retaining clip, and spent at least (16) hours out in the grueling up to 100F heat , assembling the last of the build. The downpipe was not fun! I underestimated the access issues involved with securing the WG housing bolts to the turbo...OMG! On a positive note, all the fluids are in. I've also spent (8) hours, over the last two days now, trying to write this turbo file to my ECU and got shut down again today! I won't elaborate but I'm irritated and not very happy at all!

 

July 23, 2013...


Hey, guess what?


I'M ON THE ROAD!


BUT...


We've got problems Houston...


Yet, have no fear...


HACKISH IS HERE!

 

...Spent a good part of the afternoon into the evening on teamviewer with hackish watching him do his magic. Tomorrow I'll write another file he sent me, as the result of datalogging a couple trips for him. I'm tripping limp mode at > 4000 rpm and unable to boost yet so, I'm still being kept on the edge of my seat, literally! It sure was nice though to turn the key and feel my car come back to life! I even have the front clip put back on and was able to drive it back to where I am residing, instead of in front of my brother in laws house, inside a shop, or on the back of a tow truck going somewhere!

 

July 23, 2013...

 

July 23, 2013...

 

July 23, 2013...

 

Juy 25, 2013...

 

July 25, 2013...

 

...

 

....

 

...

 

[video=youtube;NR_z_7bGr_o]http://www.youtube.com/watch?v=NR_z_7bGr_o&list=UU3CNJp0a_Y81Yfpwz65OXKQ[/video]