not the show but close enough




Ok so I had it with the overheating issues and after getting to 164,000 Miles I decided to just overhaul the entire upper engine. Yanked out the heads, and I am replacing everything from O-Rings to Gaskets.

Some pics of the engine dress up... I just finished so I didnt even want to look for the 12MP camera (G1 pics for now)
AY2 (Garnet Fire) Valve Covers


AY2 (Garnet Fire) Hydraulic Intake Solenoid




Using VHT high heat silica/ceramic paint I coated the side of the heads (Burnt Copper)



Had the DC Sports headers coated orange


I didnt opt to overhaul the lower half of the engine as the compression was good and upon removal of the heads the pistons look clean.


Tasks to complete:

Paint Front and Rear timing chaing covers
Install new timing guides/tensioners.
Install heads
Wire Tuck
Fabricate Aluminum Power Steering Reservoir
Fabricate Aluminum Radiator Reservoir
Replace S-Matic Transmission Oil
Install everything back in the car (4 Core PWR Radiator going back in after fixing the leak it had)
Fabricate Pathfinder cooling mod (unless someone shows me why i shouldn't)
Created new bushings for catalytic conv plate on transmission
Cleaned and re-taped wiring harness.






Future mods to occur (within the next week or two)

Replace fan clutch with dual e-fan's (doing more research) looking to do a 16' and 12 or 14' puller fan. (Leaving A/C fan) using the secondary as a emergency fan.

re-do exhaust to these specs:

Remove 2 bolt flanges where possible and upgrade to 3 bolt flanges to provide better seals and ease of renewing gaskets.

HKS LEGAMAX is to be altered from 2.60 piping to canister to 3.0
Setup theory:


By routing the exhaust gasses at a stepped pace will allow the engine to maximize its efficiency. Exhaust gasses move at a faster rate with a smaller pipe at the sacrifice of peak power. To maximize entire power band this theory states by gradually increasing the piping diameter exhaust gasses do not bottle neck only travel at its quickest pace by allowing less time to cool and more room to flow.

Size of pipes are as follows
2.25>2.50>2.75>3.00
This setup will alllow the gasses to travel at a higher velocity not allowing the gas to cool yet providing no backups.

(ALL MOTOR SETUP)

Current problems:

By stepping from bigger to smaller and smaller to bigger exhaust gasses create balloons. Creating a bottle neck effect, this effect creates resonance (rasp).


I have tested various setups on my car but at a consistent size not stepped.

With full 3.00 from Y-Pipe back I noticed a HUGE loss of low end power but great top end potential. also a loss of mpg.

with 2.50 noticed a nicer low end power but a sacrifice of peak power.

I will post results (and a before and after dyno at location).

 

Interesting overhaul. Cant wait to see how it looks.

 

Interesting colors, hopefullly your engine bay doesn't come out looking like a Reese's cup!

 

By routing the exhaust gasses at a stepped pace will allow the engine to maximize its efficiency. Exhaust gasses move at a faster rate with a smaller pipe at the sacrifice of peak power. To maximize entire power band this theory states by gradually increasing the piping diameter exhaust gasses do not bottle neck only travel at its quickest pace by allowing less time to cool and more room to flow.

Size of pipes are as follows
2.25>2.50>2.75>3.00
This setup will alllow the gasses to travel at a higher velocity not allowing the gas to cool yet providing no backups.
************************************************** ****

Correct me if I am wrong but in accordance to fluid dynamics, velocity of gas/liquid is higher in a narrower tube and thus should only benefit scanvenging effect

hope this helps,

 

mod list? pix of ur ride?

 

maybe he could get them to sponser this build

 

I have tested various setups and come to the conclusion to give this a test run. It is a theory.

As for f/d, velocity will be higher due to two things, heat (hot air moves faster) and tubing size.

Get a water hose and put your finger over it to create a nozzle it'll have more pressurebut it doesn't mean you'll be pushing more volume. With the finger taken out you will notice the fluid moves in higher volume with less pressure.

Have you ever inverted a nozzle? you will notice the same pressure is applied with a sightly higher volume. Imagine if the nozzle had a longer angle instead of a larger it'll allow for the pressure to continue yet move slightly more as it has less restriction.


It'll be best of both worlds.

 

In for updates (and better pics)

 

2003 Sedan

Dc sports ceramic coated headers
CrawfordZ HFC's
Full custom ss 2.5 mandrel bent exhaust to hks legamax axleback
UR stock sized pulleys
2 - 13k kw transmission coolers
PWR 4 core radiator
Grounding kit
Md 1/2 spacer with aramid gasket and tb coolant bypass
Stillen CAI with Z tube
Removed baffles from the bumpers to provide more free flowing air.
Put down stock 200/200 hp/tq
After mods 3inch exhaust. 252hp 238tq
With 2.5 exhaust 248hp 245tq (much broader powerband)

This is all untuned. I am currently working with Richard Welch of AutoSport Wiring to make a crosssover harness for an 03 to 04 ecu that way I can use the osiris tuning system.

 

what baffles in the bumper are you talking about and does it really help?

 

OP, cool similar-ish mods to mine. luckily i'm in SoCal though, so i get my tunes form Technosquare

 

have you considered one step colder plugs?

 

no need not running lean nor pinging


If i go with colder plugs it'll richen the engine off and I would definetly need a tune besides the OEM plugs are putting down good power with no issues

 

Look down on the intake and you'll notice a bunch of plastic and crap...

I noticed like a 8-10 IAT drop with the Actron after removing..

On a dyno it wouldnt get crap on the highway different story.

It's like a ram air intake you dont get a lot of gain at a standstill only on a roll.

 

oh, yeah... i keep forgetting you don't have a tune. it is in the owners manual that there are 2 heat ranges recommended. one step colder for people who live in yr round warm climates and/or are normally in the higher RPM range when driving.