After ten months of great times...

[Tmerritt530]

Shes down, and the real fun begins!http://img.tapatalk.com/46a97853-dbf6-d7aa.jpg

http://img.tapatalk.com/46a97853-dc0c-def1.jpg

[Tmerritt530]

Really considering stage 5, 3 bar, +40's, and wideband

[Orangetona]

Look at all that room. I miss G bodies :D

[Tmerritt530]

Look at all that room. I miss G bodies :D

IKR! :)

Easiest engine pull I've ever done

[Orangetona]

Yep, no special tools or any of that bs. Thats why I like TMs so much :)

[Force Fed Mopar]

BoostButton Stage 4, 3 bar, +40's, and wideband

Fixed :thumb:

[Tmerritt530]

Fixed :thumb:

Lol! How do BB cals work. Order a certain level and thats it?

[Tmerritt530]

Yep, no special tools or any of that bs. Thats why I like TMs so much :)

My only special tool is that block of wood to keep the lifting chain off the turbo coolant lines

[beeblebrox82]

Ah yes. let the fun begin.

[supercrackerbox]

Really considering stage 5, 3 bar, +40's, and wideband

Be sure to take care of that exhaust too, and look for a better intake.

[Tmerritt530]

Be sure to take care of that exhaust too, and look for a better intake.

My exhaust is 3 inch mandrel bent with high flow cat and straight through bullet mufflers.

I have a ported intake and a 3.8 minivan throttle body

[Force Fed Mopar]

Lol! How do BB cals work. Order a certain level and thats it?

Pretty much. But you can have special features added in, like launch control, alky injection triggers, Hi/lo boost switching etc.

[Tmerritt530]

Could I still use my digital boost controller? I have it set to rpm specific boost limits.

Im guessing it would be for fuel curves at that point?

[turbovanman²]

I would get the head ported, +1mm valves, S60 cam or bigger, :nod:

[RoadWarrior222]

Shes down, and the real fun begins!http://img.tapatalk.com/46a97853-dbf6-d7aa.jpg

http://img.tapatalk.com/46a97853-dc0c-def1.jpg

I see yer problem straight off, the black and grey deally on the yellow deally, should be in the middle of the red deally.

[Tmerritt530]

I see yer problem straight off, the black and grey deally on the yellow deally, should be in the middle of the red deally.

Yea that one was a real head scratcher! J/k. :)

Ill put it back in in a couple weeks!
\m/

[Tmerritt530]

http://img.tapatalk.com/46a976a8-1986-321a.jpg
http://img.tapatalk.com/46a976a8-19a0-ffa9.jpg
http://img.tapatalk.com/46a976a8-19b4-c3b4.jpg
http://img.tapatalk.com/46a976a8-19da-9a08.jpg
http://img.tapatalk.com/46a976a8-19f5-0dfb.jpg

Not so bad on the clutch. The release bearing needs some love.

[Tmerritt530]

I Stripped it down to the crank today. Here is what I have found so far:



http://farm6.staticflickr.com/5336/7437116638_48cba4b796_z.jpg


http://farm9.staticflickr.com/8007/7437125982_dceca4cb73_z.jpg


http://farm9.staticflickr.com/8153/7437130354_234644624d_z.jpg


http://farm6.staticflickr.com/5339/7437135304_3a8c687310_z.jpg


Going to have the crank out tomorrow and see what kind of shape the journals are in. The oil pump is probably shot, and I found free play between the distributor rotor and the intermediate shaft off the timing belt.

[Tmerritt530]

Oil pump is crap city. Ill throw in a melling.

#3 rod bearing did its job. Kept the crank safe.

http://img.tapatalk.com/46a976a8-2acc-f8e9.jpg

http://img.tapatalk.com/46a976a8-2b00-3471.jpg

[Tmerritt530]

Time for some updating!

First up, parts pile:

http://farm9.staticflickr.com/8013/7633562746_a52f15ee4c.jpg (http://www.flickr.com/photos/45367645@N07/7633562746/)
Parts (http://www.flickr.com/photos/45367645@N07/7633562746/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Detonation from trying to overcome seizing oil pump with lots of boost. BIG YIKES!

http://farm9.staticflickr.com/8426/7736858758_1494469962.jpg (http://www.flickr.com/photos/45367645@N07/7736858758/)
Untitled (http://www.flickr.com/photos/45367645@N07/7736858758/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

new pistons in short order:

http://farm9.staticflickr.com/8303/7759684732_f632ee4985.jpg (http://www.flickr.com/photos/45367645@N07/7759684732/)
Untitled (http://www.flickr.com/photos/45367645@N07/7759684732/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm8.staticflickr.com/7279/7759688600_611019f4e2.jpg (http://www.flickr.com/photos/45367645@N07/7759688600/)
Clevite pistons (http://www.flickr.com/photos/45367645@N07/7759688600/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

They should be sufficient for DD/occasional wild hair use.

Installed ARP rod bolts. Not Pictured: checking rod bore change after ARP's

http://farm9.staticflickr.com/8434/7762599154_1e22708494.jpg (http://www.flickr.com/photos/45367645@N07/7762599154/)
Untitled (http://www.flickr.com/photos/45367645@N07/7762599154/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Getting the clean block back from shop:

http://farm8.staticflickr.com/7113/7775409472_4303352672.jpg (http://www.flickr.com/photos/45367645@N07/7775409472/)
Off to get bored and honed (http://www.flickr.com/photos/45367645@N07/7775409472/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

---------- Post added at 03:37 PM ---------- Previous post was at 03:34 PM ----------

Adding some flair. Red paint and brass freeze plugs:

http://farm9.staticflickr.com/8441/7777751502_7682e9d4e5.jpg (http://www.flickr.com/photos/45367645@N07/7777751502/)
new brass freeze plugs (http://www.flickr.com/photos/45367645@N07/7777751502/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

oil galley inspection, clean, and plug change:

http://farm8.staticflickr.com/7266/7777754564_c992f14ab6.jpg (http://www.flickr.com/photos/45367645@N07/7777754564/)
Untitled (http://www.flickr.com/photos/45367645@N07/7777754564/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr
http://farm9.staticflickr.com/8433/7777760868_a9f2fe3e54.jpg (http://www.flickr.com/photos/45367645@N07/7777760868/)
Oil Manifold plug (http://www.flickr.com/photos/45367645@N07/7777760868/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Car waiting patiently:

http://farm9.staticflickr.com/8299/7824531546_f44dc7e44c.jpg (http://www.flickr.com/photos/45367645@N07/7824531546/)
Untitled (http://www.flickr.com/photos/45367645@N07/7824531546/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8288/7824535322_77c93437a5.jpg (http://www.flickr.com/photos/45367645@N07/7824535322/)
Untitled (http://www.flickr.com/photos/45367645@N07/7824535322/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Block at the machine shop in the Sunnen power hone. Look how that red pops in an oil bath! :love:

http://farm8.staticflickr.com/7270/7848265538_5cbe45bc70.jpg (http://www.flickr.com/photos/45367645@N07/7848265538/)
Honing the 2.2 (http://www.flickr.com/photos/45367645@N07/7848265538/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Back and cleaned of hone debris. I plugged all the oil galley openings with Vaseline before honing so no shavings could get in that deep.

http://farm9.staticflickr.com/8433/7874421130_991d771a52.jpg (http://www.flickr.com/photos/45367645@N07/7874421130/)
Bagged 2.2 (http://www.flickr.com/photos/45367645@N07/7874421130/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

The intermediate shaft cover. This thing was filthy, so I soda blasted it and had to scrape lots of hardened deposits out of it. Looks like new.

http://farm9.staticflickr.com/8180/8058493031_81ea86e9b4.jpg (http://www.flickr.com/photos/45367645@N07/8058493031/)
engine rebuild october2 (http://www.flickr.com/photos/45367645@N07/8058493031/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr



Polished the crank and put 'er to bed. Not Pictured: plasti-gaging mains.

http://farm9.staticflickr.com/8319/8058492901_5ab7a9eb3e.jpg (http://www.flickr.com/photos/45367645@N07/8058492901/)
engine rebuild october4 (http://www.flickr.com/photos/45367645@N07/8058492901/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Then I weight sorted the pistons and rods. Got them all exactly the same.

http://farm9.staticflickr.com/8461/8060939605_e6e123ec74.jpg (http://www.flickr.com/photos/45367645@N07/8060939605/)
engine rebuild october 13 (http://www.flickr.com/photos/45367645@N07/8060939605/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Matched the block oil pump opening to the Melling and installed it.

http://farm9.staticflickr.com/8032/8060939521_c3fcf5daef.jpg (http://www.flickr.com/photos/45367645@N07/8060939521/)
engine rebuild october 14 (http://www.flickr.com/photos/45367645@N07/8060939521/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Checked end Play:

http://farm9.staticflickr.com/8030/8060941790_6ed603019b.jpg (http://www.flickr.com/photos/45367645@N07/8060941790/)
engine rebuild october 14 (http://www.flickr.com/photos/45367645@N07/8060941790/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Installed Piston-rod assemblies and plasti-gauged them. All turned out well.

Then fit my crank scraper and test spun the crank to verify 1mm clearance.

http://farm9.staticflickr.com/8173/8058574992_0783579702.jpg (http://www.flickr.com/photos/45367645@N07/8058574992/)
Untitled (http://www.flickr.com/photos/45367645@N07/8058574992/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Then the end seals for the oil pan must be trimmed to accommodate the scraper.

http://farm9.staticflickr.com/8317/8058492677_3f306d0499.jpg (http://www.flickr.com/photos/45367645@N07/8058492677/)
engine rebuild october8 (http://www.flickr.com/photos/45367645@N07/8058492677/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Then the oil pan needed cleaned of all the built up deposits and oil. This was a nasty, time consuming, but worthwhile step.
I used a heat gun to loosen the grime, then combustion chamber cleaner with a brass brush. Here is the end result of my elbow grease:

http://farm9.staticflickr.com/8176/8058492455_86ed5b5810.jpg (http://www.flickr.com/photos/45367645@N07/8058492455/)
engine rebuild october11 (http://www.flickr.com/photos/45367645@N07/8058492455/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

As the block sits now:

http://farm9.staticflickr.com/8048/8075750073_0ca62597ea.jpg (http://www.flickr.com/photos/45367645@N07/8075750073/)
Untitled (http://www.flickr.com/photos/45367645@N07/8075750073/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

---------- Post added at 04:08 PM ---------- Previous post was at 03:58 PM ----------

Right now I am working on the cylinder head. My plans for it are to replace all the valves with new back-cut ones, the springs with new strength tested (so they are all consistent) springs, use the lighter retainers to reduce the likelyhood of valve float at high RPM, and use new lifters and followers.

My cylinder head:

http://farm9.staticflickr.com/8047/8075742012_d82eae8c3a.jpg (http://www.flickr.com/photos/45367645@N07/8075742012/)
Untitled (http://www.flickr.com/photos/45367645@N07/8075742012/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Parts donor head (wiped out cam journals):

http://farm9.staticflickr.com/8325/8075750421_407296ec59.jpg (http://www.flickr.com/photos/45367645@N07/8075750421/)
Untitled (http://www.flickr.com/photos/45367645@N07/8075750421/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

So today I have the head all stripped down, and am ready to start cleaning it.

http://farm9.staticflickr.com/8186/8082934114_fc9d148c16.jpg (http://www.flickr.com/photos/45367645@N07/8082934114/)
Untitled (http://www.flickr.com/photos/45367645@N07/8082934114/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8188/8082942469_fc494aac57.jpg (http://www.flickr.com/photos/45367645@N07/8082942469/)
Untitled (http://www.flickr.com/photos/45367645@N07/8082942469/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

---------- Post added at 04:12 PM ---------- Previous post was at 04:08 PM ----------

As an aside, I am concurrently rebuilding the a523 that is a known associate of this engine. It has been giving me trouble getting into third, and at first I thought the 3rd stop ring was damaged. Well, upon inspection, that is not the case. What was going on was the 3-4 shift fork dumped a pad and was engaging 3 ----eyed. It has witness marks to prove it.

http://farm9.staticflickr.com/8328/8092680801_5989b46db5.jpg (http://www.flickr.com/photos/45367645@N07/8092680801/)
Untitled (http://www.flickr.com/photos/45367645@N07/8092680801/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[black86glhs]

Will the 568 pads that Lengel makes fit the 523? Good time to get a set. Please tell me you resized the conn rod after pressing in the bolts.:thumb:

[Tmerritt530]

Yeah I PM'ed about those pads. Had rods checked and got lucky I suppose, they were still dead on with the ARP's at 50 lb-ft.

[135sohc]

If that fork looks as grooved as it does I wouldnt reuse it.

[black86glhs]

Yeah I PM'ed about those pads. Had rods checked and got lucky I suppose, they were still dead on with the ARP's at 50 lb-ft.Awesome.:thumb: I had a set that didn't come out right, only reason I mentioned it.

[Tmerritt530]

Here is another angle of the fork.

http://farm9.staticflickr.com/8049/8095127214_8380f7f624.jpg (http://www.flickr.com/photos/45367645@N07/8095127214/)
Untitled (http://www.flickr.com/photos/45367645@N07/8095127214/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[135sohc]

It looks fine. The angle of the part and the way the light was hitting it and causing a shadow made it look like there was a massive groove cut into the fork.

[Tmerritt530]

Yeah It does look a lot worse in that other photo.

[fixit]

I thought hyperuteric pistions were a bad idea for our engines ==> here is the writeup: about 2/3rds of the way down the page -- http://www.thedodgegarage.com/turbo_shortblock.html
(http://www.thedodgegarage.com/turbo_shortblock.html)
DDG- Turbo shortblock (http://www.thedodgegarage.com/turbo_shortblock.html)
Hyperutectic pistons for 2.2 and 2.5 engines

To be avoided at ALL costs on Chrysler turbocharged 2.2 & 2.5 engines. A snippet from the sealed-power webpage-

"Contains 12.5% or more silicon content. Special melting processes are necessary to ‘super-saturate’ the aluminum with additional silicon content. Special molds, casting and cooling techniques are required to obtain finely and uniformly dispersed silicon particles throughout the material. Our hyper-eutectic material is also being used in light and medium diesel engines to replace some of the eutectic pistons with iron groove inserts used for additional heat and wear resistance of the ring groove. Heat and wear in the ring groove contribute to groove ‘pound-out. In the Sealed Power hypereutectic pistons, the hard, finely dispersed silicon particles serve as ‘micro-inserts’ at the surfaces of the piston, especially in the surfaces of the precision machined ring grooves. The increased strength, heat and wear resistance provided by the high-silicon content hypereutectic piston material allows for elimination of the groove inserts in several piston applications."

Ed Peters, retired Chrysler failure analysis engineer did a study of hypereutectic pistons and this is what he determined..

1) Adding 8-16% silicon reduces excessive material waste by 25% during casting (reduced flashing)
2) Piston reject rate is reduced from 3% to less then 3/10's of 1 percent.
3) Added silicon creates pores and voids in the piston.
4) Piston cannot handle the thermal loads a turbo engine exhibits.

In short there is no performance benefit to making these pistons, it's all about reducing cost to MAKE MORE MONEY.

Want to hear Ed talk about it in detail?
You can download the MP3 file here, it's only 460k and 2.5 minutes long.
http://www.thedodgegarage.com/downloads/pistons.zip

[QUOTE=Tmerritt530;955202]Time for some updating!

First up, parts pile:


http://farm8.staticflickr.com/7279/7759688600_611019f4e2.jpg (http://www.flickr.com/photos/45367645@N07/7759688600/)
Clevite pistons (http://www.flickr.com/photos/45367645@N07/7759688600/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

How about that.

[Tmerritt530]

In other words, ill take that under consideration, next time...

[RoadWarrior222]

Bear in mind that these got the rap for being "glass parts"* back in the g-valve and afpr tuning era, when stock cals are known to go lean, so they could be fine for moderate outputs with intelligent tuning, using modern info.


(*Which is kinda funny since having a lot of silicon in might make them a form of glass :D )

[Tmerritt530]

In any case:

http://farm9.staticflickr.com/8330/8098390359_e0985b390a.jpg (http://www.flickr.com/photos/45367645@N07/8098390359/)
Untitled (http://www.flickr.com/photos/45367645@N07/8098390359/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

---------- Post added at 06:49 PM ---------- Previous post was at 06:43 PM ----------


Bear in mind that these got the rap for being "glass parts"* back in the g-valve and afpr tuning era, when stock cals are known to go lean, so they could be fine for moderate outputs with intelligent tuning, using modern info.


(*Which is kinda funny since having a lot of silicon in might make them a form of glass :D )

Bear in mind that my priority for this car is street only. No drag or other racing.

[turbovanman²]

Head cracks there are 100% normal.

[Tmerritt530]

They are? all 4 are exactly as in this picture.

Should I just cross my fingers and do a compression test when I install it?

[135sohc]

Yes those bridging cracks are fairly common.

[Tmerritt530]

Aside from the cracks. The head turned out nice:

http://farm9.staticflickr.com/8467/8101498193_bc241cb41d.jpg (http://www.flickr.com/photos/45367645@N07/8101498193/)
Untitled (http://www.flickr.com/photos/45367645@N07/8101498193/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr
http://farm9.staticflickr.com/8332/8101499221_10e9d12e67.jpg (http://www.flickr.com/photos/45367645@N07/8101499221/)
Untitled (http://www.flickr.com/photos/45367645@N07/8101499221/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[black86glhs]

Looks good.

[Tmerritt530]

Just received a box of 523 parts. Bronze shift pads! Glad to have them because the trans was grinding into third due to missing a 3-4 pad

http://farm9.staticflickr.com/8327/8110972412_3784a0430d.jpg (http://www.flickr.com/photos/45367645@N07/8110972412/)
Untitled (http://www.flickr.com/photos/45367645@N07/8110972412/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

These are a project saver!

http://farm9.staticflickr.com/8183/8114456405_5fbdc01de7.jpg (http://www.flickr.com/photos/45367645@N07/8114456405/)
Untitled (http://www.flickr.com/photos/45367645@N07/8114456405/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8047/8114465658_3e8f90149b.jpg (http://www.flickr.com/photos/45367645@N07/8114465658/)
Untitled (http://www.flickr.com/photos/45367645@N07/8114465658/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8049/8114457791_d77ce8341d.jpg (http://www.flickr.com/photos/45367645@N07/8114457791/)
Untitled (http://www.flickr.com/photos/45367645@N07/8114457791/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8474/8114458625_1179f4eaab.jpg (http://www.flickr.com/photos/45367645@N07/8114458625/)
Untitled (http://www.flickr.com/photos/45367645@N07/8114458625/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Transmission is done and clean! Now to turn back to the head and wrap that up as well.

http://farm9.staticflickr.com/8188/8117052411_b3c9b8a895.jpg (http://www.flickr.com/photos/45367645@N07/8117052411/)
Untitled (http://www.flickr.com/photos/45367645@N07/8117052411/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[turbovanman²]

They are? all 4 are exactly as in this picture.

Should I just cross my fingers and do a compression test when I install it?

Yes, Dodge even issued a bulletin on it.

Looking at the pics on a better monitor, are the seats cracked too? Some just pean over the crack with a punch, I guess makes sense, avoids a hot spot down the road.

If you have the head off, are you grinding the valves and seats? If not, at the very least, get some lapping compound and lap the valves in.

[Tmerritt530]

Yes I am actually replacing the valves with another set that is back cut so I am in the process of checking them. With dye they ride in the right spots so i was planning on some valve lapping compound already.

No the seats are not cracked

[glhs727]

nice detailed build! keep the pictures coming!

[Force Fed Mopar]

Those hypereutectic pistons will be fine with any decent 2-bar cal. Looks like a good build so far.

[Tmerritt530]

Hyperuetectic pistons were not my first choice, but cost dictated I tone the project down. I'm sure everyone knows how that is!

The stuff I am able to do now, I am doing right, so that later on I have a good platform to expand on.

Keeping it 2-bar, just setting the stage for when it is no longer my DD. then I will revisit and go forged pistons and really follow the 3-bar wild hair.

[Tmerritt530]

Valve lapping done.

http://farm9.staticflickr.com/8327/8133390267_50d1574d2d.jpg
(http://www.flickr.com/photos/45367645@N07/8133390267/)Untitled (http://www.flickr.com/photos/45367645@N07/8133390267/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

I flattened the cracks as well:

http://farm9.staticflickr.com/8045/8133390657_6a65ece245.jpg (http://www.flickr.com/photos/45367645@N07/8133390657/)
Untitled (http://www.flickr.com/photos/45367645@N07/8133390657/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Here are the valve seals l am using:

http://farm9.staticflickr.com/8192/8133417576_15a34fd5ef.jpg (http://www.flickr.com/photos/45367645@N07/8133417576/)
Untitled (http://www.flickr.com/photos/45367645@N07/8133417576/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

And here it is with rate tested valve springs installed with lighter weight retainer caps

http://farm9.staticflickr.com/8187/8137155903_dab0f0ff54.jpg (http://www.flickr.com/photos/45367645@N07/8137155903/)
Untitled (http://www.flickr.com/photos/45367645@N07/8137155903/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Cylinder head now installed.

http://farm9.staticflickr.com/8070/8165215942_7293aaa723.jpg (http://www.flickr.com/photos/45367645@N07/8165215942/)
Untitled (http://www.flickr.com/photos/45367645@N07/8165215942/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Next up is the cam. First I have to clean the rocker arms a bit.

http://farm9.staticflickr.com/8490/8165316930_79bb79ec66.jpg (http://www.flickr.com/photos/45367645@N07/8165316930/)
Untitled (http://www.flickr.com/photos/45367645@N07/8165316930/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Easy peasy.

http://farm8.staticflickr.com/7133/8165306646_2b976abbf0.jpg (http://www.flickr.com/photos/45367645@N07/8165306646/)
Untitled (http://www.flickr.com/photos/45367645@N07/8165306646/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Done with cam.

http://farm9.staticflickr.com/8210/8170559689_e6900e2ec2.jpg (http://www.flickr.com/photos/45367645@N07/8170559689/)
Untitled (http://www.flickr.com/photos/45367645@N07/8170559689/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8350/8170591132_4b84f06043.jpg (http://www.flickr.com/photos/45367645@N07/8170591132/)
Untitled (http://www.flickr.com/photos/45367645@N07/8170591132/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Now to prepare the valve cover. It is a mess.

Anyone know how diy wrinkle finish tends to turn out?

[Force Fed Mopar]

It works good, but you have to make sure it is very very clean before spraying, and let it dry about 3 days to fully cure.

[shackwrrr]

Very clean and preheat the valve cover. You will see oils and moisture seep from the pores as you heat it. Let it cool to about 90-100 degrees then spray it. Keep laying on thin even coats to build up a thick layer. Keep it warm the whole time it is setting up. Once it is done wrinkling, put it in the oven and bake it.

[shackwrrr]

http://i43.photobucket.com/albums/e357/shackwrrr/TurboMopars/Shadow/Parts/IMG_0063-1.jpg

I did it in the hot summer.

[Force Fed Mopar]

http://i43.photobucket.com/albums/e357/shackwrrr/TurboMopars/Shadow/Parts/IMG_0063-1.jpg

I did it in the hot summer.

Did you mask the lines/letters or cut the paint off afterwards?

[shackwrrr]

sanded it off with a dremel sanding drum then slightly polished.

That picture is after it was on the car for 6 months, the splotches in the front are oil.

here is when I first sprayed it.

42310

[Tmerritt530]

That is nice! What brand was that

[shackwrrr]

vht wrinkle

[BOOSTIFIED]

Good thread!

[Tmerritt530]

^Thanks! I'll keep it moving :)

http://farm9.staticflickr.com/8339/8170669041_754ee9d1f7.jpg (http://www.flickr.com/photos/45367645@N07/8170669041/)
Untitled (http://www.flickr.com/photos/45367645@N07/8170669041/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8344/8170700206_5913685bf1.jpg (http://www.flickr.com/photos/45367645@N07/8170700206/)
Untitled (http://www.flickr.com/photos/45367645@N07/8170700206/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

No damaged blades, spins very smoothly and quietly, and had no issues before I tore the engine down. Not going to be fussing much with this guy.

[Tmerritt530]

Once I get the engine broken in I can pick where to run the cam centerline:

http://farm9.staticflickr.com/8206/8173272239_fb76767b04.jpg (http://www.flickr.com/photos/45367645@N07/8173272239/)
sprocket comparison (http://www.flickr.com/photos/45367645@N07/8173272239/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8347/8175671714_c6512d53cc.jpg (http://www.flickr.com/photos/45367645@N07/8175671714/)
mopar performance sprocket P4120869 (http://www.flickr.com/photos/45367645@N07/8175671714/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Currently reading 107 degree centerline.

[Tmerritt530]

Finally got the timing system all done. It took a while for my tensioner to arrive, and when it did it was the wrong part.

The warehouse sent me a toyota corolla door handle. I couldn't "handle" it. Lol

So I had to wait twice!

Anyway I got a new water pump and heater core with the toyota part. Put the water pump on today after dressing up the housing with some aluminum paint.

http://farm9.staticflickr.com/8487/8237104000_c8492ce805.jpg (http://www.flickr.com/photos/45367645@N07/8237104000/)
Untitled (http://www.flickr.com/photos/45367645@N07/8237104000/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

The old hardware for the water pump was very rusty so I replaced the ones that are visible:

http://farm9.staticflickr.com/8339/8236038627_249f179b82.jpg (http://www.flickr.com/photos/45367645@N07/8236038627/)
Untitled (http://www.flickr.com/photos/45367645@N07/8236038627/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Tried my hand at the VHT wrinkle today:

http://farm9.staticflickr.com/8348/8243129030_4b36a587c2.jpg (http://www.flickr.com/photos/45367645@N07/8243129030/)
Untitled (http://www.flickr.com/photos/45367645@N07/8243129030/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Turned out nice! Full steam ahead.

made the A/C bracket look like something other than complete crud:

http://farm9.staticflickr.com/8203/8242073693_d12f2a341e.jpg (http://www.flickr.com/photos/45367645@N07/8242073693/)
Untitled (http://www.flickr.com/photos/45367645@N07/8242073693/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Shaping up to be a decent looking engine!

[Tmerritt530]

Installed the block off plate and screwed on a Pt turbo oil filter.

http://farm9.staticflickr.com/8198/8242430865_b740e820df.jpg (http://www.flickr.com/photos/45367645@N07/8242430865/)
Untitled (http://www.flickr.com/photos/45367645@N07/8242430865/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[shackwrrr]

Also the oil filter for a 3.7 v6 in libby's or cherokees. A lot of fords run them too.

There are lots of filters in the 3/4-16 thread range. I run the gigantic ford filter, valvoline vo1 or PH8A

[Tmerritt530]

Accessory bracket installed:

http://farm9.staticflickr.com/8344/8246025370_86278b4ec6.jpg (http://www.flickr.com/photos/45367645@N07/8246025370/)
2.2T accessory bracket (http://www.flickr.com/photos/45367645@N07/8246025370/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Black engine enamel made my rhs motor mount look awesome.

http://farm9.staticflickr.com/8058/8246027048_564888fcea.jpg (http://www.flickr.com/photos/45367645@N07/8246027048/)
2.2T rhs motor mount (http://www.flickr.com/photos/45367645@N07/8246027048/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Still haven't gotten the valve cover to the blast cabinet yet...

[shackwrrr]

Accessory bracket installed:

http://farm9.staticflickr.com/8344/8246025370_86278b4ec6.jpg (http://www.flickr.com/photos/45367645@N07/8246025370/)
2.2T accessory bracket (http://www.flickr.com/photos/45367645@N07/8246025370/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Black engine enamel made my rhs motor mount look awesome.

http://farm9.staticflickr.com/8058/8246027048_564888fcea.jpg (http://www.flickr.com/photos/45367645@N07/8246027048/)
2.2T rhs motor mount (http://www.flickr.com/photos/45367645@N07/8246027048/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Still haven't gotten the valve cover to the blast cabinet yet...

Make sure when you blast it you remove the inner baffle. I've seen a few engines wiped out when they blasted the intake and filled that baffle with media.

[Tmerritt530]

I hear you there! I have had the baffle out for a while already. No grit allowed in the new engine!

[Tmerritt530]

Ahh, thats more like it!

http://farm9.staticflickr.com/8482/8259034701_72828feecd.jpg (http://www.flickr.com/photos/45367645@N07/8259034701/)
Untitled (http://www.flickr.com/photos/45367645@N07/8259034701/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8077/8259035571_2da6e4cc6c.jpg (http://www.flickr.com/photos/45367645@N07/8259035571/)
Untitled (http://www.flickr.com/photos/45367645@N07/8259035571/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Is that a new part?

"Suuure!" (Big grin)

Pretty pleased with how it turned out!

http://farm9.staticflickr.com/8214/8262380032_83f1f65b4b.jpg (http://www.flickr.com/photos/45367645@N07/8262380032/)
Untitled (http://www.flickr.com/photos/45367645@N07/8262380032/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[RoadWarrior222]

Yah, well done, 50 points to Gryffindor!

[Tmerritt530]

Alas it is not a 1 piece...

Oh well. got lots of rtv on the shelf.

[Tmerritt530]

Valve cover and timing shield installed!

Manifolds, turbo, dizzy, and fuel rail tomorrow. Try to get to PP and clutch as well

http://farm9.staticflickr.com/8205/8267602547_44c2c15977.jpg (http://www.flickr.com/photos/45367645@N07/8267602547/)
Untitled (http://www.flickr.com/photos/45367645@N07/8267602547/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Dang rtv smudges...

[Tmerritt530]

Gotta save on my flickr space lol:

manifolds, turbo, & fuel rail

http://farm9.staticflickr.com/8339/8279676456_c8edaec193_c.jpg (http://www.flickr.com/photos/45367645@N07/8279676456/)
turbo install (http://www.flickr.com/photos/45367645@N07/8279676456/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Bogus post

[jl93sundance]

Also the oil filter for a 3.7 v6 in libby's or cherokees. A lot of fords run them too.

There are lots of filters in the 3/4-16 thread range. I run the gigantic ford filter, valvoline vo1 or PH8A

Or run a mopar 1090, i'd say thats the biggest factory mopar filter that works

[Tmerritt530]

I am thinking about what to do with my clutch. I have a Sachs clutch disc from oreilly's and a centerforce pressure plate. The pressure plate has some wear to it, not sure about the disc. I would hate to pass on this perfect opportunity to change them If I need to. They don't have much more than 20000 miles on them...

[Tmerritt530]

Transmission and engine back together.

Wedding to attend this fri/sat. Putting the engine in the car sunday

[Tmerritt530]

Engine is now in the car. Took longer to push the car back around to the shop than to drop the engine back in. Now to hook everything up and deal with axles and ball joints...

[Tmerritt530]

http://farm9.staticflickr.com/8079/8300554601_e9ba9e1f0e_c.jpg (http://www.flickr.com/photos/45367645@N07/8300554601/)
2.2 turbo with a523 (http://www.flickr.com/photos/45367645@N07/8300554601/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Force Fed Mopar]

Looks good!

[RoadWarrior222]

Apart from that one bolt he forgot..



... to the right of the 15mm craftsman wrench.

[Tmerritt530]

Thats the ground bolt for the wiring harness! After this picture I hooked up the starter harness and wrapped a heat blanket around the starter and wires. Looks like the space shuttle.

Also did the exhaust flange bolts and power steering pump.

Now I am making party food for tomorrow!

[RoadWarrior222]

Ah, thought it looked a bit short for anything else, was scratching my head.

[Tmerritt530]

If you didnt notice, there is a nut sitting on the cowl. There is a method to my madness. :)

[Tmerritt530]

The a/c belt I got with my under drive pulley doesn't fit. I have an 93ish r134 compressor not the original 88 r-12 one so it probably has a smaller pulley

But its 15 degrees out, think I have lots of time to deal with that! :)

[Tmerritt530]

Got a lot done, should be starting it this evening!

Got the next size smaller belt from oreillys, fits the ac perfectly

http://farm9.staticflickr.com/8224/8321636699_7999e90bc4_c.jpg (http://www.flickr.com/photos/45367645@N07/8321636699/)
Engine install (http://www.flickr.com/photos/45367645@N07/8321636699/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8222/8322697724_d5ef4fdeff_c.jpg (http://www.flickr.com/photos/45367645@N07/8322697724/)
Engine install (http://www.flickr.com/photos/45367645@N07/8322697724/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

http://farm9.staticflickr.com/8495/8321641905_cf01cb4f34_c.jpg (http://www.flickr.com/photos/45367645@N07/8321641905/)
Engine install (http://www.flickr.com/photos/45367645@N07/8321641905/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

[Tmerritt530]

Fuel rail is cracked. What a letdown!
I am going to have to replace it.

Sprayed fuel all over the garage

[mopardad1]

Look at all that room. I miss G bodies :D

Yeah, room. We just changed the clutch in my GLH last night, no room at all! Left the engine in, next time we pull everything as an assembly!

[RoadWarrior222]

Fuel rail is cracked. What a letdown!
I am going to have to replace it.

Sprayed fuel all over the garageThat's the automatic floor degreasing option. For if the automatic rust spray overperforms.

[Tmerritt530]

That's the automatic floor degreasing option. For if the automatic rust spray overperforms.

Lol! Well it did make the strut tower kinda shiny. Luckily none of the belts got any on them.

Going to try a FWD Performance rail. :D

[Tmerritt530]

For an interesting contrast:

http://farm9.staticflickr.com/8215/8332663700_7e334d8d44_c.jpg (http://www.flickr.com/photos/45367645@N07/8332663700/)
Comparison (http://www.flickr.com/photos/45367645@N07/8332663700/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr

Nice little refresh, huh. :)

I have to sort out my vacuum situation still. It is correct but sloppy at the moment.

Have a vacuum block and a plan!

[Tmerritt530]

Also, if anyone wants to know, the belt needed when you have an under drive pulley and an r134 compressor out of a newer car is a masterpro 15450 from oreillys. Or an equivalent cross match.

[Tmerritt530]

Been keeping busy while my fuel rail is en route.
Got a new clockspring for the car. New old stock that my dad gave to his dad. Didn't fit his application but it fits mine so we got it back! Didn't realize these we're hard to find. What can I do to make this one last?

http://farm9.staticflickr.com/8221/8355189083_ba9e2c6385.jpg (http://www.flickr.com/photos/45367645@N07/8355189083/)
New clockspring (http://www.flickr.com/photos/45367645@N07/8355189083/) by tmerritt530 (http://www.flickr.com/people/45367645@N07/), on Flickr


I have been pulling the front fascia and fenders off my red parts car so no more primer black.

The fuel rail should arrive tomorrow and I hope to have the fenders done tonight.

I hope I can do the fuel rail after work tomorrow

[RoadWarrior222]

What can I do to make this one last?Align it dead on at the rack and make sure the wheel is on straight also, then you won't be straining it the extra 1/8 turn or so if it's a little off (Or whole turn if it's a lot off)

[Tmerritt530]

It is now running! 19 vacuum.

Noisy noisy lifters, gonna pull the vc and see whats up. Probably dry too long and stuck.

O2 sensor not switching all the time. Maybe bad? O2 heater screwed up?

[RoadWarrior222]

Yah, if they don't shut up when you give them 2000 RPM for a minute or two, after warming up, then go digging, but they might just need to flush with new oil and pump up properly.

---------- Post added at 06:13 AM ---------- Previous post was at 06:12 AM ----------

Oh, if it's the heater on the O2, it will just switch really slowly at first and get quicker as the exhaust gas heats it. If it's intermittent, then that doesn't sound like the problem.

[Force Fed Mopar]

If you haven't already, switch it to 2.4 lifters.

[Tmerritt530]

I considered it during this rebuild, but i put it aside when i couldn't find the set i have. They are somewhere...

[Tmerritt530]

I swapped out some of the lifters and the noise is greatly reduced. Still no pt lifters though

[Tmerritt530]

Front end is all back on. Hood and reseal valve cover tomorrow then it is time to drive!

[Force Fed Mopar]

Do yourself a favor and find those lifters or go to the pull-a-part and grab some, make sure to get the newer ones w/ the hole in the top. Not only will it be quieter, but you'll gain some top end too ;)

[Tmerritt530]

Well i found four pt lifters. Put them in my intake sides shimmed up about .145. Still noisy. Running it up to temp now to see if they calm down

[Tmerritt530]

I had it at 200 degree operating temp for half an hour at 2000 rpm. Did not seem to help the noise. Two of the four pt lifters need some love it seems.

[Tmerritt530]

Rechecked my shims and made some adjustments, whisper quiet now! All you hear is injectors clicking away.

Just got back from a 45 minute test drive. Boy this thing is going to wanna run. Even taking it easy and doing break in stuff, this car moves.

I was most pleased with the transmission. That was a massive improvement.

[Tmerritt530]

Well the lifter noise grew back...

Luckily I found more PT lifters so i can finish the job!

On a note of concern I can smell fuel when driving but cannot for the life of me see any leaks anywhere? Bone dry

[RoadWarrior222]

Check on top of the tank and for the filler neck rotting out.

[supercrackerbox]

Also check the vacuum lines off your pressure regulator. My regulator was leaking into them, took too long to figure out.

[Tmerritt530]

Wasnt fuel after all. Misinterpreted the smell. Oil on the cowl from setting the valve cover there.

Doh!

[Tmerritt530]

Crap! I'm stranded!

Seems like the fuel pump died.

[RoadWarrior222]

Stop! Hammer time!

You can sometimes get them running by jarring the tank, best if someone cycles the key at the same time, i.e. by beating on it, kicking it, if you're carrying any spare ATF or PS fluid, then sticking a dose in the tank, a couple of "shots" worth, may help keep it running.

[Tmerritt530]

My dad and I gave it a valiant effort. But it seems to have gone from flyin high to six feet under with no in between. I'll dig into it tomorrow I just got the thing drug home

[Tmerritt530]

This is all im getting out of it.

http://img.tapatalk.com/d/13/01/20/zaga9ene.jpg

18 psi. Going to check the filter next

[black86glhs]

Yeah, its dead. Even if the filter was just clogged, they seem to die(from what I have seen) soon after replacing the filter. Be prepared.

[Tmerritt530]

Put my tester between pump and filter. Pegged past 60 psi immediately.

Looks like a new filter will fix er right up!

Thats decent news!

[RoadWarrior222]

Replace the rubber lines too, I would get a gassy smell when my filter backed up, and had a suspicion they were "sweating" gas due to pressure build up in front of filter. Often they would be bulging a bit. The fram ones DO NOT seem to last the specified service interval on my 3.0 (18M, forgot mileage) and restrict horribly when they "go". You might be SOL for finding anything but fram though, it sucks around here for that.

[Tmerritt530]

I just got the oreilly microgaurd cuz they had it.

[Tmerritt530]

Well the filter fixed my pressure at the rail, its back to spec. However, it still refuses to start.

[RoadWarrior222]

Take the battery on and off, might be flooding it now, due to trim altering hella rich as the filter got more restrictive.

[Tmerritt530]

Ok I found the REAL problem. My intermediate shaft sprocket came loose. I must have forgotten to torque it or Loctite it, or both.

So the timing belt was riding on only half the sprocket and must have skipped teeth. Now it has no timing. Looks like I get to pay my stupid tax and go back and do all that over.

[black86glhs]

Cool the filter fixed it. I never have that kind of luck. The pump always poops the bed a day or two later for me.

[Tmerritt530]

Ok, I have torqued the intermediate shaft sprocket and redone the timing. Now to put it back together and see if it will behave again.

[RoadWarrior222]

Squat down, stare it in the grille and show it the BIG hammer, the sawzall and the welding torch, it will behave for months...

[Tmerritt530]

By God I think you got it!

Back up and running. Just started over and timed it. The intermediate shaft sprocket would have come all the way off had the lower cover not been there. It held it but got chewed up badly in the process. May need a new set of timing belt covers...
I'm just lucky the sprocket bolt didn't fall out in the road! It drilled its way out through the lower timing cover.


Anyhow, that's all resolved now and it is playing nice again. :D

[Tmerritt530]

It is still behaving, for the most part. It lets me know it still has a wild side though. I think it enjoys playing with me. Wipers linkages just fell apart. This car has some personality alright... :)

[Tmerritt530]

I chasing a signal power and or ground problem right now. It will every so often read 2 psi vacuum at idle and open up the injector pulse width. Usually wont stay running like this. When it is acting up I can drive but it will die when decelerating in neutral. Just falls from 3000(or whatever) rpm straight to 0. Hmm.

[RoadWarrior222]

die on decel could be an SDS fault.

[Tmerritt530]

Boy when this thing runs right it sure is a blast.

[Tmerritt530]

Chased my die on decel to a vacuum brake booster issue last year. Just now getting around to fixing it, (been driving my truck).

Looking for the right replacement booster. Autozone shows one for 15 or 16 inch wheels, assuming thats what I need.

Dont know if it matters but i have the 11" front brake setup on the car and 15 inch crab wheels.

[Force Fed Mopar]

The boosters are also different between auto and 5-spd.

[Tmerritt530]

Car currently has an automatic booster.