I got the intake from ebay usa - didnt cost too much.

Anyhow, today I put the radiator back on, and connected the fuel line to the fuel rail, along with other little jobs.

I then took the Catch Cans and filled them with peices of foam to act as a medium to catch oil vapour and condense it. Carl had previously welded in a copper tube on the inlet.

This is because the catch cans that are sold are useless. Vapour goes in and straight back out the other tube. It is important to baffle it and make the inlet tube longer for them to do their job.

Here are the photos:

 

And also, I need a bit of help.

I have three plugs on the control harness that I cant find where they plug into. I may find it eventually but perhaps some of you know.

These are the plugs:

Grey with two connectors. Situtated near the coolant inlet and outlet to the engine:



Single connector with black cover, situated by the thermo sensor on the coolant pipe:



A very big plug with many conectors, near the battery:




If any of you know where these plugs go, please tell me, as at the moment I can find anything. My car is now completely 2.4 - engine, tranny, harnesses - everything in the engine bay is 2.4 so they must fit somewhere!

 

It looks like the big plug is: 10B - AT Transmisson Range switch.

If thats the case it wont be used. The harness and ECM were off a manual car, and it has the plugs for the MT.

 

I dont know where tose plugs go but ive been following your project for some time now and i have to say that its friggin sweet, i cant wait till you fire it up, make sure you make a vid of it so we can all experiance this momentous moment in ralliart history!!!

 

lookin good

 

Can't seem to locate this one. Can you show me where it is on the wiring harness, and get a different angle on the plug? Of course, it might be AT-specific, in which case, I'll never find it on my car.

Oil pressure switch for the MIVEC system, on the side of the cylinder head:


I even found a pic I took of it in an old thread. It's the one the left arrow points to:




This might not be right, can you take a better pic, showing the wires coming out of the plug? If it's not the AT Transmission Range Switch plug, then there's a couple other big plugs near the battery it could be. I'd like to see the wires before I send you on a wild goose chase.

 

Don't worry about that one, MIVEC is overrated anyway!

Looking good, don't scratch that valve cover!

 

that intake is sweet.. .HAH so is the rest of your car

 

Its a bit odd that my wiring harness has both AT and MT plugs on it. thanks for the help though ill have a closer look now.

 

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Well, if your MT doesn't start shifting all by itself you're good I think...


BTW: If your original tranny was anything like the one one the base model Lancer over here, you are gonna be so amazed at the RA tranny! Did you think of installing an engine damper (Zaklee) though? 'Cause I predict you are gonna grind that 2nd gear if you drive the thing anywhere near it's peak performance potential...

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Not with the brass shifter bushings installed! Although that damper will help with wheel hop.
Can't remember......Diavlo did you get the stiff motor mounts from RRM?

 

I have posted about this before. My buddies Civic has an AEM intake and he wanted the bypass valve. We put it on the car about a year after he got the intake and it broke in like 10K miles. I would only put this on my car if I had to traverse a deep body of water every day. And then I would check it for stress cracks at least every other time at the gas station. Total piece of junk and a waste of time.

 

Today was a day of nothing working right, except the fuel pump, which went in easily.

Here are the things that went wrong:

1). My engine doesnt have an oil pressure sensor installed just a bolt in its place. I need to order that sensor - that was for unconnected plug # 2 above

2). Old 1.6 Left-hand Drive Axle doesnt fit - need to order new 2.4 one.

3). unconnected plug #1 is for the brake fluid resevoir which on a RHD is on the opposite side of the engine bay - so it should be extended over to there. Problem is, my 1.6 has a plug for that coming out of the harness that powers the lights! I guess i disconected that and and connected the 2.4 control harness plug.

4). Cant tighten the axle nuts to 181ft lbs, 150 is as much as we can get.

 

Here are some pics of the problems and finally the completed fuel pump.

1 - Engine Oil Pressure Switch plug, and place the E.O.P.S should be (allen head bolt).



2). Plug for brake resevior on 2.4 harness near ABS and MAF..



3). 1.6 Plug for brake resevoiur on Right hand light harness.



4). Close up of place where engine oil pressure switch should be.





Completed fuel pump from return to returnless:

 

I should also add that the actual engine was from an SUV we have here, which must have had MIVEC disabled. They have done this by having an ECM that omitts mivec and have replaced that pressure switch with a bolt.