Random car updates

[DCIV]

Random updates, I have a lot of them.

So after I got the timing back right I noticed the boost gauge wasn't reading the correct vac and just didn't have the power it should. So I pressure test and find lots of leaks. Fix a bunch of small ones. Had a good sized one I couldn't find. In the meantime I decided to go for a small test drive. Wife said she wanted to come with me. Well....I shouldn't have done that. Little did I remember that 2 years ago when I replaced the water pump, I was more interested in if I messed up the heads. So when I retimed it and tried to start it, once it didn't I walked away. Fast forward to our test drive, car starts to get hot....had to stop...I remember, almost instantly, I forgot to put coolant in it. Had to have someone bring me some coolant, started and temp went to where it's suppose to.

I go back to pressure testing and it took a good 2 hours chasing with a water bottle and soap but I finally found it....lower intake manual. How does a lower intake start to leak with a metal gasket. It leaked before the test drive before anyone says that. But it didn't leak when I pressure tester 2 years ago and does now. Grrrrr.

I still wanted a compression test in correct time. So I did that as well. Front 3 cyl are all 110 on the dot, on a cold engine. The rear is a little different. Closest from timing belt first. 120/115/110. Don't know if I should be worried about that or not.

Anyways, I need to order new gaskets for the lower intake manifold and prob upper while I'm at it.


Coop

[mjannusch]

Ran with no coolant? Ugh.

For it to get hot enough to show hot on the temp gauge means that the air in the coolant passages had to get hot enough out to the sensor. Without fluid flowing, you get really hot areas on the heads. Hopefully no warping on the heads.

Keep an eye on the water pump too. That bushing in there doesn't last long without fluid as a lubricant.

[DCIV]

It wasn't run hot long, the sensor showed hot, it got shut down, it was like 230 on my data logger. I'm sure it wasn't good, I'm sure it's not the end of the world. Don't you think there is some sort of assembly lube when putting together something like a water pump? It couldn't of had more than 5 mins on it. I bet it's find too.


Coop

[DCIV]

Got the lower intake manifold off this morning. Spent a lot of time just cleaning the surfaces making sure there is no stuff in the way of a clean seal. I think when I was trying to start it forever it left a lot of gas that broke down the black part of the gasket.

Anyways, those gaskets are ordered and should be here by 1 this afternoon. Taking some time and fixing a couple other things that were tiny leaks. Hopefully this thing will get a good pressure test today.


Coop

[DCIV]

Grrrrr. Just put on the new gaskets. Granted felpro but heck I liked their multi layer better when looking at it. Tightened in a circular pattern once just so it touches, once to a tight feeling and then once to torque spec. Put it all back together....leaks. Freaking leaks.

Are Mitsu gaskets that much better? Should I order those? Should I look to see if something is warped? Do I just need a new lower intake? I hate taking off the fuel rails and injectors just to to put them back on. Very frustrating.


Coop

[DCIV]

Has an idea that it was injector insulators and not lower manifold as you all know you spray soapy water it bubbles but trying to see down there is hard. I had a spare set, swapped those out, leak is MUCH better! But it's still leaking at the lower intake. Like around the bolts and stuff. I'm only pressure testing to 15...not like it's 30 or more. I'm tempted to let it heat cycle and then try and retoroque them. I mean it was MUCH better. Just when I did it last time it was nothing. I had it at nothing.


Coop

[DCIV]

Eh pumped it up a little more....the leaks were way worse. I guess all I can do is order some Mitsu gaskets?


Coop

[BATMAN]

Might be the lower intake itself

[DCIV]

That's what I'm starting to thing.


Coop

[DCIV]

I have another lower intake....on another vr4. I'm tempted to go take it off to see if the lower intake is the problem...or something much worse.


Coop

[Duck Vader]

Do it.

[DCIV]

I guess I have to, I just hate tearing that car apart even more!


Coop

[BATMAN]

A lot of dressing has to be removed to get one single bolt.
Have fun.

[DCIV]

The other car is 30 mins from my house. So an hour total...drove there...wrong key. Couldn't pop the hood to get to the lower intake. Not going back today.

Minus the lower intake, could the heads have gotten to hot at some point and warped there? Is there a way to check it? Can lower intake mani's be decked? It's just hard for me to fathom warping a cast aluminum intake. Like...that's some hot stuff.


Coop

[DCIV]

Pulled this lower intake again. I don't have a true strait edge but I do have this thing from building a t-square...it's pretty damn strait. I can't see any warping in the lower intake. I can't see any dirt in its way. I can't see why it didn't seal. I am almost at the point to put down a small layer of rtv and bolt this bitch down. It really makes zero sense. I want to reassemble. But then again I don't as if it doesn't work I have to take back apart and try another lower. Then do it all again!!!!


Coop

[DCIV]

To some very light sandpaper to the manifold then really cleaned it with rubbing alcohol. Got everything just as clean as I could. Took off the gaskets, whiped them down, put it all back together and wouldn't you know it 3 if my bolts that go from the upper plenum into the lower just gave away. I mean I had this thing off and in so many times in the past couple days that it's crazy. Well I tightened the ones that would and it leaks at the upper now but I don't think the lower. Hard to tell.

So I know heli coils screw down into the threads....do I need smaller bolts then? Same bolts? How do I put those in? Never had to do it before.


Coop

[aaronatstate]

[quote=""DCIV""]To some very light sandpaper to the manifold then really cleaned it with rubbing alcohol. Got everything just as clean as I could. Took off the gaskets, whiped them down, put it all back together and wouldn't you know it 3 if my bolts that go from the upper plenum into the lower just gave away. I mean I had this thing off and in so many times in the past couple days that it's crazy. Well I tightened the ones that would and it leaks at the upper now but I don't think the lower. Hard to tell.

So I know heli coils screw down into the threads....do I need smaller bolts then? Same bolts? How do I put those in? Never had to do it before.


Coop[/quote]

You buy the helicoil kit for the size threads you already have. You then have to drill out the holes slightly, tap them with the tap that comes in the helicoil kit, and then install the helicoil. You can then reuse the stock bolts. The two helicoil kits I have bought have had the tap, but not the drill bit. My drill index has the bits I need, so it hasn't been an issue for me. Both kits were expensive, $30+ on Amazon. I think it's because of the bolts being large diameter, fine pitch metric bolts though.

[DCIV]

Cool, I know fasinal here has kits. I guess thurs I will go get a kit.

Coop

[DCIV]

So heli coils were easier than I thought. Did the ones the upper intake bolts too. Only one didn't wanna go in after...looking strait down the hole with a light and the upper bolted down it looks strait. I guess I'm gonna back all of them out and get that one going first. Tightened it all down, minus the one, and hit the pressure tester real quick....still leaks somewhere. Someone at work mentioned that I have the gaskets on backwards.....seeing as I don't think that can happen....is it possible? Can you put them on backwards like the tb gasket?


Coop

[DCIV]

Still leaks!!!!! What the freak.

I am done playing. Tomorrow it gets taken apart and studs. It WILL stop leaking.


Coop