Topic: tperkins' Evo 3, 6, 7 (and 5 RIP) (and Starion RIP)

[tperkins]

Gang gang.









Washed it yesterday, I have a really hard time wanting to put this car under the knife and have downtime from driving, since it is just so great. People laugh at my accumulating spare engines, transmissions, transfer cases but the days are coming when they get very hard to find and I legitimately want to keep this car forever.

Also, I realized that we agree that a GC Subaru is the best looking Subaru.

And, now we know that you enjoy a black evo 4-5-6 above a GC Subaru.

Therefore, you enjoy a black evo 4-5-6 more than any Subaru. *gasp*

Can't believe this didn't get any response, I for one was shocked.

[jellynuts]

I didn't want to get flagged for hate speech.

[tperkins]

I didn't want to get flagged for hate speech.

They send you a warning.

[diamondedge]

They send you a warning.

LOL oh man this never gets old

[tperkins]

Bonus updated GN pics

[jellynuts]

If your car was the same colour as the Buick, it'd be perfect.

[tperkins]

Finally getting around to things on the 5, parts pile is secured, I don't think I need anything else for assembly.

As the engine bay had an engine explode in it, then it had the dipstick of the new engine pop out a couple times, it was filthy and not a fit home for the new engine.
I didn't get any pictures of the before as i was just embarrassed at how gross it was

Partways through cleaning


Hood before, see grossness


Some nice tin snips clearance that I found, with the 4g64 this car had, it also had a rotated turbo and honda civic half rad, as well as some beefcake intercooler. I am not sure for which of those this clearance was done for. The cuts also were left unpainted lol.

This side looks like it was done with a an actual cutting wheel but the other side was full on tin snips.

After, clean bay, fixed hood insulation. I borrowed a pressure washer from my friend, pressure washed everything, then used superclean and this little electric dishwasher brush you can see in the tin snips thing. Honestly looks like fresh paint IRL afterwards.


Fixed nice tin snips



Reposted picture, but I similarly didn't have pictures of the before of the engine because I was also embarrassed how dirty it was. Reminder that this engine was pulled from a running evo 6, compression tested well across the board, healthy running engine.


I didn't get many pictures of the process, but here is after cleaning, sanding and painting block, etc


Cleaned and painted spark plug cover


I had the old exhaust manifold covers from the 6 that were in a lot better shape, I cleaned them and painted them


I also cleaned the trans and t case with a tooth brush, and just wasn't happy with the finish of the cases anymore, so I painted those as well (great masking job).I went to Canadian Auto Paint Supply and they actually had paint for exactly this purpose.


Time for timing kit, water pump, etc.

[tperkins]

Hooray, timed things, new water pumping things. Those keen observers will notice that the oil pump sprocket isn't lined up in this, but this was after timing was set, engine was turned over a heap of times to verify timing.


I also had noticed the timing cover warped, the plan was to put it back in place with some cardboard spacer behind it and between the cam gears and the cover,

The plan failed



New timing belt, balance shaft belt, all pulleys, hydraulic tensioner, water pump, valve cover gasket set, accessory belt (car had AC removed, would be a real pain to put it back)

[10secdream]

Is there any reason you didn't remove the balance shafts? I am just thinking back to my DSM days (4G63) and it was pretty common to remove them.

[tperkins]

Is there any reason you didn't remove the balance shafts? I am just thinking back to my DSM days (4G63) and it was pretty common to remove them.

I am part of the club that trusts Mitsubishi engineers over keyboard warriors. I really don't see the value in removing it is all, just didn't put much thought into it to be honest haha.

[10secdream]

Ya it was just a question. I was just under the impression that when you remove it there is less moving parts for something to fail and freeing like 1-2hp on drag for a tradeoff of more noise.

[tperkins]

Ya it was just a question. I was just under the impression that when you remove it there is less moving parts for something to fail and freeing like 1-2hp on drag for a tradeoff of more noise.

Sorry, I didn't mean you were keyboard warrior or to sound like a dink haha. I mean people in the DSM / evo community on both sides of that debate.

I think the trade off is the possibility of the balance shaft belt snapping and taking out the timing belt. But, when I get the car running I am just going to upload the evo 7 ralliart tune, dial the boost to 18lbs and call it a day. In my head, mitsubishi engineers likely put it in there for some good reason, every part they have to include and machine costs them money, so be it trading some parasitic loss that the butt dyno wouldn't even be calibrated for in exchange for vibration / engine longevity I just decided to leave it! I really didn't think of it too much haha

[10secdream]

Excellent points and I agree.

[tperkins]

Evo fam had a brand new evo 8 upper timing cover sitting on his project engine, so I bought that. These things warping must have been an issue, the old one is just a flat bit of plastic on the back, newer one has actual structure back there.



Broke this silly stud, I was lacking a bunch of tools so I brought it to local machine shop, was quoted 96-198$ to remove it, so I went to my evo friend's house and borrowed some tools. Ended up having to drill it all the way out, after easy outs gave up just waffled it inwards with a pick and hammer.

Of course was offended at the dirtyness off all the hotside components so cleaned up the castings and painted them with the same flameproof I used on the 6, seemed to work pretty well on the 6. Cleaned up the casting marks inside this manifold and opened it up a little as well.


Between coats sanded this biz


Brand new studs (other than that top left one, on the way out that one broke two of these aluminum stud extractors I was using... it came out 3/4 of a turn and then just stopped dead. Upon removal I was probably putting 60-70 ft-lbs into it trying to remove before it would bust the aluminum stud extractor, so it is plenty strong. Learning my lesson from last time I just decided to leave it as the fastener is still in good enough shape, all though that isn't ideal. When I torqued it down it worked out just fine.)


Most of the biz re-assembled




When I bought the evo 7 ECU, the seller asked what I needed it for, told him about the project and the engine and blah blah. Anyways, when he shipped the 7 ECU he also included a much nicer crank pulley (see engine), an intake manifold spacer (not gonna use), like a 1000 km old o2 sensor, a brand new ball joint, a used but good fuel pressure regulator, and a brand new wastegate actuator.


Unfortunately, this wastegate actuator seems to be from an evo 9 turbo.. so the arm is too long. Gonna make it work somehow today and bolt the engine back together so it is ready to drop in. Next step is to remove the hacked evo 5 harness (thanks tuning shops) and put in the almost unmolested 6 wiring loom (with sweet HKS SPEED DEFENCER). Once that is done then just have to remove engine from stand, bolt up trans and new clutch kit, then bolt in engine. Plug in the things, blah blah blah.

[Canuckrz]

No clear timing cover for your greddy timing belt and hks adjustable timing gears?

For that actuator rod you might be able to throw a die on it and cut the threads a bit further back as it looks like you're not too far off.

[tperkins]

No clear timing cover for your greddy timing belt and hks adjustable timing gears?

For that actuator rod you might be able to throw a die on it and cut the threads a bit further back as it looks like you're not too far off.

For setting the pre-load, you should do half spins until it can just slide on, then 3 full spins (count 6 faces). So, even though it is just about to slide on I am 3 full turns from that point too long as well.



The way this arm is set up there isn't much material to thread unfortunately. That was my first hopes as well. I think if I drill a new lower hole in the bracket it will work though!

Haha, clear cover to show off my gates belt and stock cam gears! Almost as cool as when people just drive around with no cover at all!

[jellynuts]

It's going to be a racecar, not a showcar, right?  Really nice work all around though.  Keep up with the updates!

[tperkins]

It's going to be a racecar, not a showcar, right?  Really nice work all around though.  Keep up with the updates!

"Not every show car is a race car but every race car is a show car"

I just really have a hard time with doing things not as well as I can, but who knows where this car will go at this point haha. I just want it to look nice.

[tperkins]

Hole seemed to have worked!



Decided to paint the spark plug cover


Cleaned up the harness

JDM AF

[tperkins]

Turns out I had a couple of pictures of before engine


And I was busy this weekend so didn't get anything done, last night when the rain stopped I went and cleaned up the headlights.They had this weird, maybe clear coat, maybe 3m spray on them that was flaking off.

Before reminder

[jellynuts]

headlights... had this weird, maybe clear coat, maybe 3m spray on them that was flaking off.

A grinder can easily clean and polish that off. 

[Asstuna]

A grinder can easily clean and polish that off.

I'm proud of you, my son.

[tperkins]

A grinder can easily clean and polish that off.

I actually took a can tire kit with the palm sander and put a 1/2" drive on my drill, cut a slit into the palm sander, then shoved it in. I had to hand sand the 400-600-800 but the 1000 and 3000 I was able to do with drill.

[diamondedge]

A grinder can easily clean and polish that off.

I went and cleaned up the headlights.They had this weird, maybe clear coat, maybe 3m spray on them that was flaking off.

Or just get someone to do it for you for free.

[Canuckrz]

Or just get someone to do it for you for free.

Just don't tell them its someone elses car.