Last Weekend:
In place of the Christmas tree of AN adapters, I now have an appropriate NPT to -4AN fitting sealed into the block with teflon tape. Additionally, I believe a PO tapping the block to NPT was the source of the metal in the journal bearing of the turbo.
Also just about finished mounting the turbo. PO was missing one stud on the downpipe side, so I had to order one. I did not like how the stainless Manzo coolant line kit I had was going to fit, so I used HPS high temp silicone heater hose for the coolant lines instead. I also went with a cleaned out stock drain tube for similar reasons. So far I have only used the braided feed line from the kit. Live and learn (or save for a CST-4 later? )
This Weekend
This weekend was quite mild so I was able to get a lot done on the Speed. I was able to start wrapping up additional maintenance items that were side effects of this project. This included securing the Manzo downpipe to the cat-back exhaust, installing replacement tensioner and idler pulleys, putting the serpentine belt on, splicing a new throttle connector on (old one had melted/exposed copper by the plug), performing an oil change. Other items were replacing vacuum lines with silicone hose where applicable, installing and routing the catch can and check valve, installing the remaining downpipe stud and O2 sensors and wrapping up the rest of the reinstall items.
Question: Do people use a 3" donut gasket between long downpipes and the cat-back exhaust? the Manzo pipe did not come with one and I suspect I have a slight leak at that joint as there is no donut gasket.
Finally I was ready to start the speed up. I pulled the injector fuse and cranked the car in sessions until the oil light went off. I cranked it another 2-3 times to ensure that the turbo was primed with oil before starting. I then gave everything another look over before installing the injector fuse, taking a breath, and turned the key...
The new starter coupled with all of the maintenance/update items resulted in the engine turning over nicely and catching the first time with ease. The only apparent issue was I still had a CEL and the throttle was unresponsive. With codes P0123 and P0222, It made me question the splicing I had done on the throttle connector. Fortunately, upon inspection of the connector, some ID-10-T (me) hadn't fully plugged the connector in.
Once the throttle was plugged in properly, she fired up and idled quite nicely. I let the car idle for almost 20 minutes as I checked for leaks, waited for the coolant system to burp from being topped off, and burn off the oils from the exhaust system. HPFP pressures looked good exhaust sounded nice and everything seemed to be in order. I shut the car off and am letting it cool before a final inspection and buttoning up the undertray and TMIC cover.
Observations
Has anyone had their OEM damper pulley separate? I noticed a fair amount of degradation in the rubber between the hub and counterweight portions on my pulley. I may have to see about replacing it at some point before it decides to part ways with the rest of the car.
I did also notice that the TMIC heat soaks like crazy with no airflow. With an IR thermometer I was seeing surface temps on the top back side of the TMIC between 130* and 140*. I am thinking about possibly adding some kind of reflective insulator to the bottom of the top back end tank of the TMIC to help with heat rejection from the Turbo.
Additionally, I have been toying with the idea of doing an Air-to-Water intercooler replacement for the TMIC. Based on the placement, a TMIC has some downsides that I am not fond of for long term reliability and longevity. Airflow (or lack there of) from being on top of the engine isn't great, along with the heat soak issues don't help intake air temps. Another option is switching to a FMIC, but most clod side routing I have seen are quite long and go over the engine. If possible, I don't want to add excessive length to the cold side , adversely affecting throttle/boost response. I do have a large FMIC core I could use however so we shall see.
Next steps
1) Now that she is running, its time for new shoes. I am probably going to get Goodyear Eagle Exhilarate tires in 235/40-R18 to go on the 18x8 OZ rims that came with the car.
2) Unfortunately in the last 7 months sitting, the windshield has developed a pretty bad "Y" crack. A replacement will be in order after tires.
3) Continue working on the body and Misc. other items such as hail dent removal, some small scrapes/rust spots, de-glazing and sealing the right headlight
4) Do some data logging with Mazdaedit and tweak accordingly due to catless downpipe and 3" to turbo intake (hopefully adding a 3" MAF housing in the process).
