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642 rebuild


blue642
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Galant VR-4 org Post #: 823552 posted 08/24/09 05:41 PM     Remind Me!  Send Private Message   Edit Post      
For those who read my initial introduction post on 642/2000, you know what a mess the engine bay and trunk were. Rausch saw it when it was in Dan's hands and can attest to the state of hack it was in. Initially set out just to fix up the loose ends to get it running and then drive it, but once I started digging into it relized that I may as well pull everything, fix it right, and throw it all back together so that I know its done right.
So here's the before pics:

The major kill factor of it was the way he spliced into the wiring harness, the poor hose routing, the fact that it was spray painted over the oil/dirt leaving a tackie feel to it, oh and the fact that it looked like S*@#!!!

Here's her part way cleaned after everything was pulled:

And after paint:

While everything was out, I stripped all the engine brackets off and repainted them, as well as the valve cover, and intake. I was amazed at all the shady work I found, like a zip tied CV boot . Also took this time to get familiar with the wiring harness and the service manual. Strip all AC, PS, ABS, and the unneeded emissions (no checks around here ).

Then I started reinstalling everything, with the new goodies.



I still have quite a bit to do in the engine bay, but I figured I'd post some progress and get some feedback. I haven't even touched anything else yet. Going to be fixing the sending unit flange on the gas tank and reduing all the wiring for the battery in the trunk this week, as well as buttoning up a lot of the loose ends in the engine bay.
The other big one is new FMIC and piping. I ordered an EVO8 off ebay, but it never came and I'm still trying to get my money back
If anyone knows a good deal on one let me know.

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Terrance362
needs moar imput
565/2000


Galant VR-4 org Post #: 823682 posted 08/25/09 07:00 AM     Remind Me!  Send Private Message   Edit Post      
Try Garfeild, he might have some.



565/2000
699/2000


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blue642
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Galant VR-4 org Post #: 823724 posted 08/25/09 08:57 AM     Remind Me!  Send Private Message   Edit Post      
Thanks.
PM'd him

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Rausch Galant VR4.org Moderator
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Galant VR-4 org Post #: 823738 posted 08/25/09 09:47 AM     Remind Me!  Send Private Message   Edit Post      
Looking good man!



Rance lives here...
Founder of Sold out to BMW Cru, then sold out there too.


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blue642
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Galant VR-4 org Post #: 823779 posted 08/25/09 11:45 AM     Remind Me!  Send Private Message   Edit Post      
Thanks. Still got a ways to go. Finished machining some new shifter cable bushings yesterday w/ some spare nylatron that I had for paintball gun bolts, and some solid shifter mounts. Should firm thing up a lot. Now if only someone would send me pics of some SS brake lines, that would finish off my pedal/shifter feel list

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Rausch Galant VR4.org Moderator
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Galant VR-4 org Post #: 823780 posted 08/25/09 11:47 AM     Remind Me!  Send Private Message   Edit Post      
I know- I suck.



Rance lives here...
Founder of Sold out to BMW Cru, then sold out there too.


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blue642
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Galant VR-4 org Post #: 824137 posted 08/26/09 11:20 AM     Remind Me!  Send Private Message   Edit Post      
Installed new shifter cable bushings yesterday. Nice fit.
Also grabbed some pics of the new shoes, plus a free pair (ie they came with my golf which was free) that I'm considering.

17x7 +40 offset exel ennios w/ kumho ecsta supra 225/40s


and the debateable:
18x7.5 +42 ICW DV8s which need new tires.


Will get pics of both on the car to see how they look. Keepin the stockers for winter.

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Besso
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Galant VR-4 org Post #: 824142 posted 08/26/09 12:05 PM     Remind Me!  Send Private Message   Edit Post      
those first ones kind of look like momo sports. I love those wheels


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blue642
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Galant VR-4 org Post #: 824202 posted 08/26/09 03:35 PM     Remind Me!  Send Private Message   Edit Post      
Not to fond of those momo's personally. Always wanted a set of momo evo 3s though.

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blue642
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Galant VR-4 org Post #: 824424 posted 08/27/09 11:11 AM     Remind Me!  Send Private Message   Edit Post      
Finished up the spacers for under the radiator and got it in its final mounting position (not fully bolt though bc its coming back out to get fan mounted).

Also got the rest of my goodies in for hooking up my battery.

Ran 0 ga for power and ground up to engine bay. Going to get terminals and everything else on tonight.


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turbowop
Hard Snarker
1051/2000



Galant VR-4 org Post #: 824633 posted 08/28/09 03:20 AM     Remind Me!  Send Private Message   Edit Post      
You really didn't need to run a ground wire all the way from the trunk to the engine bay. Just connect it to the top of the rear shock mount and it works great. I also would have ran the large power wires through the huge grommet behind the splash guards in the passenger front wheel well.



-Mark

A face only a grocery shopper could love.
1051

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blue642
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Galant VR-4 org Post #: 824642 posted 08/28/09 06:55 AM     Remind Me!  Send Private Message   Edit Post      
Heard mixed on the ground in trunk, but it was grounded back there when I got it and it was having some serious flow issues. Moving battery up front solved it temperarily. If I learned anything from my comp stereo days though, its that having the battery, engine, and chassis all directly grounded to eachother is Always better then using chassis as central ground. Not neccessary, but gauranteed to flow better/crank over easier.
Might look at that grommet and see if it works better though.

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blue642
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Galant VR-4 org Post #: 824643 posted 08/28/09 07:00 AM     Remind Me!  Send Private Message   Edit Post      
Finished removing the ABS control unit, g sensors and all of its chassis wiring last night. didn't get around to buttoning up the battery though.
We'll see if I get anything done this weekend due to weather. If nothing else, I'll make an EGR blockoff, and new shifter bushing. Might even make a new bottom portion to the FPR to mount it straight to rail depending on how the internals look.

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blue642
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Galant VR-4 org Post #: 826441 posted 09/03/09 07:12 PM     Remind Me!  Send Private Message   Edit Post      
Been swamped at home/work and haven't gotten a lot worth posting done. Found that the driver seat mounts were pretty rusted right where they bolted down, so I cleaned them up and put two coats of POR-15 on them. Made up a set of delrin shifter bushings and solid mounts and got it all put back together. Finished installing battery in trunk, ran wire for EGT, and finished wrapping the front engine bay harness. Still have to wrap the engine harness, but once thats done, the FMIC and piping will be all thats left under the hood.

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blue642
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Galant VR-4 org Post #: 828192 posted 09/10/09 06:17 AM     Remind Me!  Send Private Message   Edit Post      
So haven't gotten a lot done this week. Might be picking up another car though. 91' GSX, auto , clean chassis, bone stock, but not running. He thinks its the CPS, but not sure. I should be able to get it for 400. Not sure for driving or parts yet, but if its parts I'm splitting the cost with my friend and he's doing a turbo conversion on his laser. Keep posted on how that pans out.

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blue642
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Galant VR-4 org Post #: 828632 posted 09/11/09 09:42 AM     Remind Me!  Send Private Message   Edit Post      
Finally got an FMIC setup on order thanks to Jason (shiskibob).
ended up working like 12.5 hrs yesterday, so I only had to work 3 hrs today since we're not allowed to work any OT. That means I should get a lot of stuff buttoned down this weekend.

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blue642
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Galant VR-4 org Post #: 829464 posted 09/14/09 07:04 AM     Remind Me!  Send Private Message   Edit Post      
Got that GSX that I'm looking at running. Had leaky cap in ecu, and a pos bov venting to atmosphere w/ no plug on the intake side recirculation hole, and a snapped fuel return line. Runs pretty smooth now, though it still has some issues (hole in sending unit, radiator fans aren't working, and who knows what else)
On the Galant end, I finally started sorting through some of the details this weekend. Finished wrapping and tucking the engine wiring harness, moved the FRP (again), mounted a 240sx windshield washer resivoir where the ABS unit was, and figured out where my AFC and third gauge were mounting (decided to squeeze them in CD player slot). Also picked up some SS brake lines and A pillar pod from Aaron. Try to get up some pics tomorrow.

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Rausch Galant VR4.org Moderator
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Galant VR-4 org Post #: 829592 posted 09/14/09 03:31 PM     Remind Me!  Send Private Message   Edit Post      


Was nice meeting you! Think the car is in good hands.



Rance lives here...
Founder of Sold out to BMW Cru, then sold out there too.


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blue642
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Galant VR-4 org Post #: 829823 posted 09/15/09 06:16 AM     Remind Me!  Send Private Message   Edit Post      
Same here. Now it just needs to run

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blue642
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Galant VR-4 org Post #: 831877 posted 09/21/09 06:50 AM     Remind Me!  Send Private Message   Edit Post      
So there was a big 42# box waiting for me when I got home on friday. Finally got my intercooler setup!!! Got it test fit and did some shorter rerouting, then stripped all the pipes down and repainted them, as well as polishing and painting the end tanks. My gaskets won't be in till tuesday, so no pics of the setup till then.
I'll be making some mounts for my radiator fan today, as well as some other misc items like EGR blockoff,caps for AC holes in firewall, and ring for sending unit in tank.
Teaser cell phone pics



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blue642
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Galant VR-4 org Post #: 832239 posted 09/22/09 06:30 AM     Remind Me!  Send Private Message   Edit Post      
Capped all the ports on the TB, made EGR block off plate, rad fan mounts, and caps for holes in firewall yesterday. Got home to late to install any of it. My gaskets are suppose to come in today, so I should be a able to finish install everything this evening.

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blue642
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Galant VR-4 org Post #: 836065 posted 10/02/09 11:53 AM     Remind Me!  Send Private Message   Edit Post      
Weathers been crappy so haven't been to motivated to finish everything, but I've been chipping away and hope to turn her over tomorrow.
FMIC setup is all repainted and installed, plumbing is done, wiring is fully wrapped and mounted, radiator fan mounted, did most of the fluids yesterday (1.5:1 MTL:MT90 in transmissions, lightweight shock poof in transfer case, and castrol 10W30 in engine). Got my hardlines that mount on the struts yesterday. Still have to get them and my braided stainless lines in and everything bled.
Also finally dug into the gas tank which I've been avoiding. All studs were broke, half of the mount that goes around the sending unit holes lip was ripped up, and there were 9 holes from various hacked mounting attempts (2 holes were actually from a hose clamp that was cut in half and the ends screwed into the tank about 4 inches from the hole, then tightened down to hold it in place ). So I removed the rest of the ring and JB welded all the holes last night. I'm going to POR15 as much of the top of the tank as I can see when I get home. The plan is to drill the 6 holes for new studs in the tank. I turned a ring and locktited 5mm bolts into it to make new studs. I then cut it in half so that I can get it into the tank. I'll then bolt them in place using jam nuts. Then I'm making a dam and around the lip about an inch wide. I'm going to then fill that in with epoxy to give a solid, flat, surface to seal too. Should be cured by tomorrow morning. Might even get to drive it this weekend

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Garfield Wright
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Galant VR-4 org Post #: 836076 posted 10/02/09 12:27 PM     Remind Me!  Send Private Message   Edit Post      
Sam,
With this clean build you're doing, I'd make sure those ic pipes are cleaned up. They look out of place on such a clean car .

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blue642
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Galant VR-4 org Post #: 836136 posted 10/02/09 03:51 PM     Remind Me!  Send Private Message   Edit Post      
Thanks. I take that very highly given the quality of your setup from what I've seen.
Those pics were from the rough fitting when I got everything. They've since been, fully stripped, sanded, and painted. The IC end tanks were sanded smooth to get rid of the cast finish and painted as well. All gloss black now (with the exception of the core which I didn't want to put any more paint on then what was already there.

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blue642
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Galant VR-4 org Post #: 836821 posted 10/05/09 07:12 AM     Remind Me!  Send Private Message   Edit Post   
Well I worked on the Galant all weekend and can't get it to run. I finished the gas tank Saturday morning and the new studs and epoxy mounting ring setup appears to be working very nicely. Bolted up nicely and there are no fumes. Also wired up a relay for the pump with 10 gauge power wire coming from the battery.
Had a few issues when I first went to turn it over and got them sorted out, but somethings still up. Acting as if my ECM isn't turning on. No spark, no fuel coming out of injectors. I know its something stupid, just not what. My laptop's hard drive had crashed earlier saturday taking my copy of the service manual with it. Couldn't dig into it the electrical at that point. I'm going to be sorting through it tonight to see if I can get it figured out. I loaded another copy of it onto my external hard drive, so I'll just steal my sister's laptop.

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