28 replies to this topic

[QUKNEZ]

Hey guys,

 

I am in no-wise a motor mechanic or claim to be. My knowledge of cars is very, very basic but I'm all for giving it a good go before I pay someone to do it for me. So here we go...

 

Day 1 of giving this overhaul a try and I'm already over it! lol

 

Hoisted the car and placed safely on jacks. Removed tires and tried cracking the caliper bolts but couldn't do it.

 

Time for a snack.

 

Removed air intake and pipe(s) to radiator. Removed resevoir and radiator caps and bottom hose. Drained the coolant. Disconnected bottom cabling and removed radiator/fan. 

 

In the pic, it shows the engine bay without the radiator. Question: Whats that long skinny grey pipe from the front of the car leading down past the turbo? Is it to do with Air Con or something? Can I take it off? Im thinking that it'll get in the way once I do the turbo swap.

 

Went back to brakes. Generous application of penetrating spray. Still no good. Another snack.

 

Question: Its still 'lefty loosey - righty tighty' for these caliper bolts yeah? Just making sure. I'll get a longer breaker bar tomorrow and tackle it again.

 

Back to the engine bay. Removed all associated bolts to the rocker cover as per instructions found on this forum. Removed wires but couldn't get the plugs out coz they wouldn't stick to the socket I was using. I just couldn't be bothered so they stayed in. As per instructions from this forum I used a long flat screw driver to pry the rocker arm up but it felt a bit tight? I didn't want to over do it so I didn't go any further with it. I also found that with the rocker arms closest to the cam gears they wouldn't lift up at all, so I wanted to know if anyone has any tips on trying to get to the lifters from this point on. I'm thinking that I need to just undo the rocker arms altogether from the cams so its easy access to the lifters? Any help on this would be cool coz I'm not sure where to go from here.

 

Next was undoing the manifold. Seemed to go ok with again, generous amounts of penetrating spray but the end washer is wedged between the actual bolt its on and I think it was part of the engine mount or something thats just beneath the cam gears? So basically all the bolts are undone, but when I try to take it off, the washer keeps wedging itself preventing me from pulling it away fully. I did actually push the turbo down a bit to make some room, and it did, but then I thought that was probably not a good idea..lol

 

So any ideas on getting this thing off? I'm thinking grind off the washer? but I will wait for further instructions lol

 

Well, that's all I cared to do today. To be honest it felt good to get in there and give it a go but Im looking forward to seeing if you guys can give me a hand.

 

...by the way, TD05 hasn't arrived yet. Hopefully in the next couple of days..

Edited by QUKNEZ, 26 August 2014 - 11:15 AM.

[leadfoot]

long skinny pipe is Air con related (do not undo it!) you'll loose all the gas and be up for a re gas it clears the td05 fine

 

to get the exhaust manifold off cleanly you'll need to take the power steering pump bracket off.

[QUKNEZ]

sweet. I'll take that bracket off today and see how it goes.

 

If I undo the bolts on top of the cam shaft, will that free up the rocker arms enough so I can access the lifters? Im thinking that if this is the case then I wont have to actually pull out the cam shaft and worry about messing up the cam gears?

[BMGTZ]

if you take the cam caps off you will remove the tension on the cam belt and have to redo the cam timing and also recompress the hydraulic tensioner.

[BYBY5L]

Just cut the edge of the washer,
why fuck around with the p/s pump bracket everytime ya wanna take ya manifold off, and if the corner of ya mani hits, grind the edge so it fits,

[QUKNEZ]

Well, Day 2 and pretty much if I didn't unscrew it, undo it, get it off or make it fit then I just went and did something else on the car then came back to it. Worked a treat coz I pretty much got to do most of what I wanted to without pulling my teeth out.

 

With a really useful link from Django I managed to pry all the rocker arms up and get all the lifters out without too much drama. I just had to crank it a bit each time I came to a tight rocker arm because the cam was in the way. That explained that tightness from yesterday. Just got one lifter that popped out and got conveniently stuck deep in the head that I need a magnet and long nosed pliers to get out. I thought the lifters in there were the original 4g93 ones with the really small top hole but they were the oversized ones, but man did they NOT budge one bit when I tried to compress them! All of them were tight az and are in need of a good clean or I'll just biff them. Got my new lifters (from Meeks) and soaked them in a bath of oil to be ready for tomorrows bleeding and installation.

 

After a trip to the local, I got a breaker bar and some other goodies and that took care of those stubborn calliper bolts. I had trouble getting the rotor off but nothing the hammer couldn't solve.

 

Sadly while I was on a roll I ran out of time, but I'm pretty happy with the progress I'm making. Like I said, I'm a novice when it comes to this stuff but its cool working on it. Still waiting on the TD05

[QUKNEZ]

Is this the installation kit that I need to install my TD05?

 

http://www.ebay.com....cb663838&_uhb=1

[Ian91]

That's the kit I bought and I needed to but 2x 90 degree fittings for the oil feed and also the 19mm nut on the end of the water lines hit on the turbo centre when you bolt the onto the banjo bolts. I fixed this by putting 2 copper washers under the banjo bolt instead of 1. I don't know of any other kits you can use though.

[QUKNEZ]

Yeah I havent seen anything like it anywhere else. Ive followed your progress with yours and Im hoping I dont come up against anything out of the ordinary with mine. I'll be hitting you up if I do! lol

[Ian91]

Yeah I havent seen anything like it anywhere else. Ive followed your progress with yours and Im hoping I dont come up against anything out of the ordinary with mine. I'll be hitting you up if I do! lol

You might not have issues with a standard manifold. Or maybe they sent me the wrong hoses because vin18m said his oil feed was really long

[QUKNEZ]

Yeah I saw that. Hmmm..sending different parts aye? I dont have a standard mani, custom s/s from a fellow forum member so it should be interesting when I get it all together...lol

[VIN18M]

It'll probably be easier with the custom manifold because you can run the oil feed between the runners.
I had the same issue with the block off bolt on the front of the turbo, ended up using a 90 degree speedflow fitting to space it away from the actuator arm.
I'll try and get some pics to show how I did it.

[QUKNEZ]

yep, be cool if you can mate.

 

Funny thing is, I was dumb enough NOT to take photos before I undid everything so 'good luck' to me with remembering how it all goes back together! lol

 

Day 3 Yesterday and it was a huge success with installing my primed lifters. Using the instructions from the link I was able to use 2 big long flathead screwdrivers and PRY my way to getting them all in. $5 pen magnet saved my life and sanity sooooooo many times during this whole process. But as soon as I got the hang of it, it was all good. Just made it so much easier cranking it every time the cam lobes got in the way. Made sure to depress all the lifters while they were in to double check. Instructions said for me to crank it a few revolutions to make sure the lifters were all good, which they seemed to be.

 

Just waiting for the rocker gasket to come in hopefully today and I'll seal it all up.

 

Can anyone recommend an effective way of applying the gasket sealant/hi temp silicone when installing the rocker gasket and cover? Never done it before and dont want to get it wrong.

 

Also does anyone know the torque specs for the rocker cover bolts? Actually for any or all of the engine bay bolts that I need to do up? Any links or info would be great

 

TD05 still hasnt arrived

Edited by QUKNEZ, 28 August 2014 - 10:23 PM.

[leadfoot]

http://www.ebay.com....=item337399c0f8

 

is what i have in the head can't seem to find the same kit i used which had a really long oil feed hose

 

you can reuse your td04 drain and i think the kit i bought was marketed as tdo4 but can't seem to find it

[QUKNEZ]

Day 4 yesterday and was restricted on time to do anything substantial. Attached one rotor and caliper bracket but noticed that one of the caliper slider bolts has a bit of rubber on the end of them. Didn't notice it when pulling them out coz they were that greasy. But which one goes on the top or bottom of the caliper? The rubber ended one or the other one?? Also, when putting the rotor on am I suppose to put lube on the back of it to make it stick a bit more so that its sitting flat on? 

 

Managed to get the mani free but in the pic is the washer that is preventing me from pulling it right off. As you can see its flush up against what seems to be a bracket attached to the belt and cam gears. I obviously didn't want to mess around with loosening that so it stayed. Might just do what was suggested and grind the washer off and get one thats not so big.

 

Cleaned the rocker cover with brake cleaner and let that drip dry overnight. Quick once over on the head to clean obvious gunk but will do a last clean up today on the head and cover. I found a previous forum post on installation and torque specs so I'm good to go but thanks for all the replies regarding that guys...lol. Just remembered that the rocker gasket I ordered wont be in till Monday but on closer inspection it looks like the one I pulled out looks ok to put back in. I will make an executive decision today whether I will roll with it or wait till Monday.

 

TD05 wont arrive till next week which is too late for me so I'll install that hopefully with EVO ecu and injectors once I have them.

 

Any pointers on anything here guys? I know its ez-peezy stuff to yous and might not be worth your while but I appreciate your comments

 

 

file://localhost/Users/sulusieteru/Pictures/IMG_5200.JPG

file://localhost/Users/sulusieteru/Pictures/IMG_5201.JPG

[QUKNEZ]

why cant I attach pics?????

 

Edited by QUKNEZ, 29 August 2014 - 11:43 PM.

[QUKNEZ]

DAY 5...glad its over.

 

Just did the front brake pads and rotors with no problem. I've seen that many clips on it...lol

 

I need my car back on the road for Monday so I just went with my original head cover gasket and made sure to seal her up real good. When I was cleaning her up beforehand I noticed a crack near one of the screw holes, obviously from over tightening from the previous owner so that pretty much confirmed in my mind to go ahead with the old gasket. For now I just need her on the road so when I eventually get the new rocker gasket I'll install that once I get a new rocker cover in the near future. 

 

Anyone know of a 4G93 rocker cover for sale? lol

 

Had to tackle the mani with that messed up washer blocking its exit. I had no grinder so I just took to the ol' flat head and mallet and hammered away at it until I split it all the way through (took me frickin' ages!?!?!?!!) wedged it out and off came the mani. Placed the new one in and mounted it on the TD04. Reinstalled the radiator/hoses, air intake, etc. Double checked everything.

 

Put radiator flush in and filled with water.

 

You's weren't joking when you said it would be as loud as anything when you turn her on for the first time?! It took ages for it to quiet down a little but after like 20-30mins it was still making noise...but not as much. Did I still need to give it more time? I put the front wheels back on, pumped/tested the brakes a bit and thought that maybe a slow drive around the block might get things going in there. Still a bit of noise. Do I still need to give it more time?

 

But here's the twist. As I left the driveway, I put it into 1st gear, or so I thought, and started driving and almost stalled it realising in the end that I was actually in 3rd gear. The whole time around the block I couldn't get into 1st or 2nd gear. Nothing. Double pumping the clutch, forcing it far upper-left hoping it would get in there. Nothing.

 

I read another thread on here about a similar thing not being able to get into gear and he fixed it replacing the master and slave clutch cylinder. My master cylinder looked full. No leaks in the cabin. Could this be the problem? If so, how did this even come about as my gear changing before this had no problems. Or, if it isn't...anyone have any ideas? 

 

I'm stumped and now without a car for work    

Edited by QUKNEZ, 30 August 2014 - 10:53 AM.

[BYBY5L]

Like ya method of the cutting the washer, lol

have ya checked ya linkages on ya gearbox?
does shifting feel notchy or does it start to pull when in gear with clutch in?

an with ya rocker cover, is the crack inside the seal ot on the outer ring? If its outside the sealing perimeter just use that one for now

[QUKNEZ]

Like ya method of the cutting the washer, lol

have ya checked ya linkages on ya gearbox?
does shifting feel notchy or does it start to pull when in gear with clutch in?

an with ya rocker cover, is the crack inside the seal ot on the outer ring? If its outside the sealing perimeter just use that one for now

Honestly mate, I had no choice with the flat-head and mallet with no grinder on hand? Never again. lol

 

I'll check the linkages...but I don't even know what I'm looking for in that regard?

 

Shifting is ok 3-4-5-R. With the clutch in, I pushed hard upper-left and it felt like I was in 1st, go to 2nd and then it felt like going to 3rd was really, really close to 1st and 2nd as opposed to 5th and R if you can understand what I mean? Thats why I always felt like I was in 1st, but I was actually in 3rd.

 

Just wondering how anything I did would have affected the linkages. I obviously must have done something without knowing?

 

Hmmm...getting confused trying to figure out where it is and how it corresponds to what your saying...lol

Edited by QUKNEZ, 30 August 2014 - 12:12 PM.

[BYBY5L]

Get someone to move the shifter around and look under your air intake pipe, you'll see a couple of levers getting moved around, Maybe its something as simple as something in the way or a clip slipped, follow them up an see if ya can spot anything
does seem odd seeing ya didnt do anything, maybe ya bumped something