drfink's clean 89 turbo 4wd wagon build
drfink
Wagonist
About 6 weeks ago I purchased this 88 wagon that had a blown motor. 285k on the clock. someone had swapped in a single cam nonvtec zc in it.
as you can see it's been mainly used as a parts shelf as i've been collecting things to begin my build.
i pulled the old motor, took the head off and found this:
ouch. it looks like someone dropped a valve and then drove on it for like 30k miles lol.
bought a d16z6 for $150. the guy told me it was ok. surprise it has a spun rod bearing. i was going to just drop it in but now that its pretty much junk i decide to rebuild it. luckily the crank out of the single cam zc was in good shape so i used that. and whats the point of rebuilding it stock?
dropped the block off at the machine shop to get bored out for 75.5mm vitaras, honed, decked, notched the block for custom length rods, and surfaced the head.
75.5mm vitaras
p2p0 rods
stock head
edelbrock performer x
act 4 puck clutch
arp everything
anyways i got the block back the other day so i decided to start a build thread. started putting the bottom end together today, and ran into a snag because I didn't read the directions on the ring compressor i bought, so i bent one of my oil control rings on piston #1. nuts. anyways here's the block as it sits right now:
i had a dyslexic moment and for some reason was thinking backwards so i put the arrows pointing the timing belt instead of the flywheel. so tomorrow i have to flip those 2 pistons around lol. or i may just decide not to and say fuck it and run them toward the timing belt. ill probably flip them though.
i also felt like bragging that my holes for the int shaft were already tapped! HA!
anyways if anyone has a driver side fender in good condition hmu.
as you can see it's been mainly used as a parts shelf as i've been collecting things to begin my build.
i pulled the old motor, took the head off and found this:
ouch. it looks like someone dropped a valve and then drove on it for like 30k miles lol.
bought a d16z6 for $150. the guy told me it was ok. surprise it has a spun rod bearing. i was going to just drop it in but now that its pretty much junk i decide to rebuild it. luckily the crank out of the single cam zc was in good shape so i used that. and whats the point of rebuilding it stock?
dropped the block off at the machine shop to get bored out for 75.5mm vitaras, honed, decked, notched the block for custom length rods, and surfaced the head.
75.5mm vitaras
p2p0 rods
stock head
edelbrock performer x
act 4 puck clutch
arp everything
anyways i got the block back the other day so i decided to start a build thread. started putting the bottom end together today, and ran into a snag because I didn't read the directions on the ring compressor i bought, so i bent one of my oil control rings on piston #1. nuts. anyways here's the block as it sits right now:
i had a dyslexic moment and for some reason was thinking backwards so i put the arrows pointing the timing belt instead of the flywheel. so tomorrow i have to flip those 2 pistons around lol. or i may just decide not to and say fuck it and run them toward the timing belt. ill probably flip them though.
i also felt like bragging that my holes for the int shaft were already tapped! HA!
anyways if anyone has a driver side fender in good condition hmu.
Comments
Then I went and educated myself about Vitara pistons. I wasn't aware that the Suzuki engine rotates the other way. You should definitely turn them around.
yeah i did last night already. the wrist pin is slightly offset towards the major thrust angle of the engine. people have successfully run them both ways, in fact a lot of domestic guys have been messing with reversing pin offset and things like that for years, but i went ahead and flipped them around.
got the engine in today just gotta finish hooking up the coolant lines, wiring vtec, vacuum lines find a new purge control valve solenoid since mine is apparently broken, and go get a new throttle body from the junkyard since when i was dropping in the motor i accidentally tore the plug off my tps sensor. i guess i could just use the purge control valve off the z6 manifold. i wanted to get an ls throttle body anyways so no worries.
also still waiting for my 4 wire o2 sensor to come in the mail. and i gotta find a p28. but, she'll be firing up soon, then she'll be off to get emissions and plates, and then the turbo setup will begin!
note: the edelbrock performer x BARELY BARELY fits in the engine bay.
i hope it will be! plan is to run a 16g and shoot for ~300hp.
http://www.youtube.com/watch?v=t96xafVtrPs&feature=youtu.be
first start up was today. started up on the first crank! finally. ended the day with new axles in, and the car finally on the ground too. i was happy about it finally being off jackstands. the guy i bought it from had let it sit for a couple months before selling it, so itll move under its own power for the first time in quite a while tomorrow. just gotta fill up the tranny with fluid, and she'll be ready to go!
Also had kind of a nerveracking moment before all this happened when I first tried to take it out for a spin, popped it in 1st, let the clutch out, and it didn't go anywhere. My friend suggested I might have put my clutch disk in backwards, which I proceeded to freak out about until I realized my passenger side axle wasn't fully seated in the transmission. A couple hammer blows and she was good to go.
here's a quick video of a test drive i made:
http://www.youtube.com/watch?v=JZWJDT8ATWQ&feature=youtu.be
oh yeah, i relocated my battery to the back. dont worry its a sealed battery before everybody jumps on me about toxic gases in the cabin.
to do still:
exhaust (obviously lol)
fix my slow heating up problem (suspect stuck open thermo)
rear u joints
upper & lower ball joints (have parts)
inner & outer tie rod ends (have parts)
emissions test (gonna try and get it to pass, hanging that i'm gonna drive down and register it at my buddy's house in pueblo, no emissions down there)
get a god damn driver side fender
rust repair (anybody got a shell i can chop up for panels? lol)
turbo
zex 59300 cam
paint (thinking about SI blue, opinions?)
so still a long way to go. but the project has come along immensely since i first started.
update: scored some minty gsr cloth seats and a gsr cluster at the junkyard yesterday. got the seats sitting in there right now, working on bracketing them up to sit nicely. cluster swap coming soon! and pics lol.
got the seat brackets mocked up, my buddy's coming over with the welder tomorrow to weld em up
READINGS LIMIT RESULT
HC GPM 1.5461 2.0000 PASS
CO GPM 9.7367 20.0000 PASS
CO2 GPM 313.7254
NOx GPM 3.5521 4.0000 PASS
ordered a traction bar so i can make some brackets and unghettolean the radiator, may have to do a little clearancing. gotta get the exhaust sorted and gonna start tuning
as far as a filter on my turbo is concerned, i have barely any room in front of the turbo so i'm going to use one of these
http://intakehoses.com/Merchant2/merchant.mvc?Screen=CTGY&Category_Code=CHEW
and then run a filter on that.
excuse the zip tie bumper & radiator mounting job, its temporary until i can find a better mounting solution and you know its effective lol
im probably gonna reloom the wiring today just been lazy
traction bar is in. Replaced front strut and spring with some ones that had lower mileage that I took off my buddy's wagon when I installed some coiloversurn for him. Front clip on, DSM 450ccs in, and I started tuning. Intake setup is on. U joint came in, replaced it and put in my driveshaft. Ordered a zex 59300 cam. Waiting for my check to come in so I can go get my exhaust done. I want to keep a nice quiet tone so I am contemplating either doing 2.5" downpipe with 2 resonators or a 2.5" downpipe to a 3" exhaust with two resonators. I'm really not sure if it will make that much of a difference at the power levels I'm shooting for anyways.
The filter is just a ghetto one I had laying around, I have ordered an aem dryflow. I plan on shortening the 4" piece of pipe I have between the cobra elbow and filter a little and then making some kind of airbox around the filter, then making a duct from the front to direct in air. I know it's a little sketchy right now pointing down, but it's better than no filter and I'm just careful not to drive through any puddles lol.
just a quick shot of when I swapped out the cam for the zex 59300.
Got my exhaust done today. 2.5" downpipe to 3" exhaust.
In for mooore