1998 Evolution V GSR: Classroom

[Solar]

No way. Really in ?

[Tim_M]

Brian: In is defined as off the engine stand and sitting in the engine compartment with one mount connected and a jack under the oil pan. We do have all connections to make...but at least my landlord won't kick us out if he comes for a viewing!

[Tim_M]

We continue to analyze all the connections...most appear to fall into place once we begin - scavenger hunt in some cases...

Few minutes today to install a new front badge:



Complete!:



And used an entire roll of paper towels to work on this:



Probably not worth is, but clean is more enjoyable...

[Tim_M]

Not much improvement, but I feel better. Installing a new throwout bearing (the new fork lacked a bushing - oops):



Popped in the refreshed OEM injectors (we hope they will be too small!):



Some young lady fun...jeez - stay on task!:



Back to the trans...on the move - balanced on a floor jack...precariously:



And Installed...hairy leg is mine...she was a bit too fragile for this part - served as eyes for the block to bellhousing alignment. Once we realized the idler pulley and belt tensioner should be removed to allow the motor to drop angle further - it all fit together...with some muscle:



Positive progressive!

[Tim_M]

Good 8 hours in the garage today...finally!

Idler and belt tensioner reinstalled:



Starter installed:



New slave installed...after working the clutch fork to engage the clutch collar successfully! Then bled all the black fluid out - first time I've gotten to work the pedal while someone else turns the bleeder - nice! And big news is we have full clutch movement - little concerned over the twin disk install:



Then to the intercooler pull and rinse out of debris and in this case quite a bit of oily residue which I would expect is normal:



Simple Green to the rescue! Rinsed several times...:



Drying setup...that hairdryer has many garage hours on it!:



Drained the transmission...hadn't been serviced recently - the rather impressive drain plug magnet contained an impressive amount of debris:



Assistant went about refilling the box with nearly 2 quarts of fluid until she mentioned it seemed to be draining out another hole in the transmission! Well, guess we should wait to refill until the transfer case is install - appear to share some fluid pathways...oops.

We did arrange the shifter cables appropriately and popped them on (missing the hardware though!)...and we have gears! Little lady couldn't wait to hop in and do some gear jamming! Shifter seems a ok...at least statically.

Much time was used finding the correct or close enough bolt from the stash. Couple of cases we resorted in trimming a few threads - interesting she loves the Dremel...so did I as a kid (and adult)!:



Transfer case weigh in...59.6 pounds:



Fun shot:

[Solar]

Yikes! You Go Dermel girl !

Can’t wait to see a video of that engine running. Is it close ?

[Tim_M]

Brian: I do see that the glove is minimally on the wrong hand of the assistant. She gets frustrated at the lack of dexterity with the Mechanix...even the X small variety.

We are close...have to plumb few gauges and still to drop the tank to swap the pump...exhaust is still inbound...speaking of which...

Shot of the exhaust:



Full 3 inch, 200 cell cat, and extra quiet build (longer muffler/resonator).

[Native]

[Tim_M]

Returned from 30 hours in the woods leading 15 Scouts in wilderness survival...I need a vacation now!

Second order of 'T' adapter fittings arrived - this time German made vice the Speedway Motors in Nebraska (Chinese!). The first attempt did not have enough taper on the threads to allow even starting thread engagement. Hopefully these are acceptable as these seem to be geared toward hot water systems...SS metal construction:



The install above the transfer case (not yet installed) into the back of the block - the OEM sensor and the Autometer sender:



And the 60 pound transfer case...bench lifted with little fanfare as it quickly guided its way home and bolts easily accessed. 5 of the 7 are new as they were nowhere to be found - glad Mitsubushi parts are plentiful!:

[Tim_M]

Another piece to the puzzle arrived - custom UK exhaust...full 3 inch with CAT. Weigh in is 32 pounds complete. The previous Fujitsubo setup was over 50 pounds...



CAT:



Good sized tip:



We also received a set of 1050 cc ID injectors...hoping to surpass the current OEM injectors...hoping:



We have another Saturday dedicated to the 3d puzzle...making headway!

[Tim_M]

Productive day!

Front axles installed...and wheel bearings torqued to 177 NM minimum:



Gearbox refill on-going...this time it didn't leak out as fast as she put it in thanks to all parts actually installed this time!



Coolant sensor harness reset due to Evo 5 harness with an Evo 6 thermostat - no wire cutting though:



Finished product:



New cam gear cover due to chunk missing of the original...not to mention lacking any 'seals':



Battery relocation platform install:



Little bit of soldering - she quite enjoyed the liquid metal:



End result:



Polishing the new ground connection - really enjoys the Dremel although that wire wheel left its mark - she now wears gloves...:



New airbox intake tube with metal Evo 9 recirculation valve - clean!



Even pulled this line to replace two semi flattened o-rings - hope that solves the static leak:



The list of tasks seems to grow!



Does anyone know where this goes?



End of day:

[Tim_M]

Had a short spell today...family consumed most of the day:

Project came with a seemingly good aluminum radiator...quite robust too! Little extra room to install:



Temp installed the gauge package...still need connections - hate to drill any holes in the auto, but this seems low impact and when closed is out of sight - mainly these are for tuning and/or issues:



Now they are invisible:



Current shot - looking pretty good!

[Native]

It IS looking pretty good!

[Tim_M]

Steve: Thanks!

Our new baby battery showed up today via Amazon.de. ~$80 for the 540 crank "quadruple A" size weighing in at just under 22 pounds. Not much reserve power there, but...



It fit (with the relocation tray) and we applied power after being 6 years idle. Nothing let the magic smoke out!:

[Solar]

Wow, looky theres a engine in that car ! Where is all the hacked up wiring and cut AC lines ? Oh thats right, an adult is supervising all the work. Goof job, I liked the old battery better with the Bull on it though. Is the engine making any kind of noise yet ?

[Tim_M]

Brian: Luckily this for the most part is simply reinstall as OEM. Can't get any easier especially Japanese at that. But still lots of work (fun). The bull battery did look much cooler than a...'Varta.' No starter movement yet. Still lacking a few hoses and coolant, etc. Possibly this weekend if we can retrieve our downpipe that is getting a bung installed for the wideband sensor. Not even sure the program in the car will work...haven't a clue on how to log/tune this thing. We will enlist an expert!

[Tim_M]

Pumped the diff and transfer case full of 75W-90 fluids.

Reassembled the right rear brake/wheel and reversed course on the fuel tank disassembly. It was decided to not drop the tank at this time...priority is to get this running and road legal and follow up over the winter on a few areas. We assume the fuel pump will work...

Also neglected to install the OEM windage tray for various reasons (I forgot)...so off came the pan (relatively easy):



Full exhaust shot...nice 3 inch full thru...hope the neighbors won't hit the ceiling!



And the M2 downpipe installed...unfortunately, the bung we had welded in for the wideband O2 sensor was installed about 10 degrees higher than requested...running directly into the transfer case - not going to work:



We will try to use the blocked off bung in the cat pipe...flipping the cat end for end so the wideband is on the front side of the matrix. Possibly further back than ideal, but currently just want to ensure we aren't pig rich on start up.

[Tim_M]

No music this weekend...

Added oil (10W-30 VR High Zinc Oil):



Added coolant:



Added 5 gallons of 98 octane fuel:



Even hung the new exhaust with huge tip:



We pulled the plugs and hit the starter to 'prelube' the engine. Funny...didn't hear any hum from the fuel pump. Keyed the ignition multiple times to no avail...silence. No fuel came out of the engine compartment fuel filter either. We reseated the one engine fuel relay and fuel pump connector.

So...image showing us draining 5 gallons of fresh 98 octane fuel:



We have a multimeter on the way...assistant's enthusiasm waned a bit...

[Native]

Oh gosh. Sounds like you've got a plan though... that's good!

[Tim_M]

The Evo seems to have a bit of a complex electrical system...two relays, one for high pressure (WOT) and one for low pressure (part throttle)...but relays are hard to come by - few parts that are no longer available.

Nonetheless, we had a new pump and so down the tank came. Not easy or clean, but no show stoppers. Lots of 'shells' covering the top of the tank thanks to nature making their home for 6 years. Successful in avoiding any spillage into the fuel, we believe. The real challenge was dropping it enough to pull the fuel pump module out...which was solidly connected to 2 hardlines at a 90 degree angle of 14 inches. They fixed this on later models, like most modern cars, I suppose.



Unfortunately, what was inside was a Walbro pump...same we were installing - known for its reliability.



But, several key motions to the car, we had fuel squirting out the belly of a loose fuel line! Don't know if the old pump was jammed (it worked on the garage floor afterward), loose connection, or...) So back in the fuel went:



Due to lack of Assistant time, I worked the gauge install a bit - primarily the AFR and oil pressure, but in the end did all 4 simultaneously since they all used the same routing...waiting for Assistant to work the 'liquid metal' (solder) portion:



Used a hanger to poke the wires thru:



This port under the right front fender...perfect!:



Uncovered this mess...believe it to be a turbo timer...turn the car off and this device keeps the motor running for a set time to cool the turbo...I would like to remove it, but the bundle scares me a bit - will hold on that action until later: