Hey Guys,

I am going to post pics with this story, but please keep reading past the pictures as I am looking for advise and help on what is going on here. I am very technically inclined and understand my car pretty damn well, but I am at a loss at this point. Help is much appreciated!

Months back my stock motor (+ cams) went on my IX at 394whp/384wtq. Before the motor went completely, I had an issue two-three times where my spark plug in cyl #2 would crush into the electrode.

Since then I have done the following:

Buschur 2.1 shortblock was purchased assembled and ready to go. I had the head completely redone with:
Supertech bronze valve guides
Supertech valves
Supertech dual valve springs and Ti retainers
port/polish
Topline "no-tick" lifters
ARP L19 head studs
Re-used my Cosworth M2 cams and factory cam gears.
All new timing components, and OEM Mitsu gaskets for re-assembly.
The car was then re-tuned by John at The Shop (who I enjoyed working with very much).

After about 500mi on my new setup, I pushed a freeze plug out of the block. I contacted Buschur and they sent me a new one, which I resealed.

After about 1,000mi on my new setup, My intake cam broke in half at the oiling holes for the MIVEC system. Luckily no other damage was done, I reassembled the car and put some GSC S2 cams in.



Then, only a couple hundred miles later, I blew a ton of coolant out of the side of the motor. The water pump gasket was leaking. I contacted Buschur and they advised me that my head probably wasn't sealing properly and I had a bad headgasket. I was frustrated at this point with the car, but argued with myself that maybe somehow I ****ed up. I pulled the head once again! *BTW - I am now a pro at doing my timing belt :|
I had the head re-decked and stainless o-ringed. I put the car back together.


*Well here I am again... after 500mi I take the car out and play with it a bit - and for the first time broke it while I was actually having fun with the car under boost (not just joy driving). I shifted through 2nd-3rd-4th gear under boost, and felt a odd hesitation going into 4th. I boosted the car again to see if it was my imagination and it blew a cloud of smoke. I kept driving and watched my oil pressure til I could find a good spot to pull over and take a quick look under the hood. The car was driving fine normal. I saw some oil under the clear timing cover, but nothing pouring to the ground.

I got home and pulled my plugs. Cyl #2 spark plug had almost all of the insulator completely missing again (like my first motor -same cylinder too!),and Cyl #4 plug the insulator broke and carried to the top of the plug. I looked down on the top of the pistons that had the bad plugs and they are super clean -leaned out??? The other two good cylinders are black as night from carbon buildup.


Couple quick notes- I have noticed the lifters have been very loud on the car since I put it back together this last time. I am still using my PTE 780cc injectors that have been in the car since I bought it, and re-used my MIVEC cam gear. I don't know if the MIVEC gear can screw up and cause anything like this to happn.

For now, until I get further into the car, this is all the info I have. I have to do some more troubleshooting and will keep the thread updated. I am looking for experienced engine builders and tuners to post on here because I need help this time around. Thank you!

 

Thats tough!

 

Send the injectors out to get flowed, possible that they are partially clogged.

 

did you do any logs at all? you didnt reuse the headbolts did you?
id check the injectors like the post above says, maybe the othe 3 are rich and making up for Cy#2 leaness as the O2 Wideband will pick up Average AFR for all 4 cylinders. unless you got one of them fancy 4 cyclinder AFR setups.

 

+1 on doing any logging while running it. How did the AFR's and boost look during your pulls? I also agree on checking the injectors since that could obviously caused leaning out. How is the fuel pump? Any idea of the duty cycle of the injectors? I assume you are running pump. Have you ever ran e85? Since we all know you can get buildup from various stations that could cause insufficient flow. Just throwing some stuff out there. Also what type of plugs and heat range are you running? Have you tried any different ones?

 

Did you modify the mivec cam gear for the taller deck height?

What fuel are you running?

 

Car is strictly 93 oct only. I did re-use the L19's as they only had a couple hundred miles on them. I made sure everything was torqued 100% when assembling the motor.

I did not modify the MIVEC cam for the taller deck height - please elaborate on this since I don't know what I would modify. Car is running 27psi and IDC gets upward of 90-95% under high boost. AFR's are about 12.5 under initial spool and quickly drop to 10.8-11.2 as boost comes on.

I actually did log the car the other day and was getting some odd knock count and could feel it (probably was one of the plugs going or gone). I replaced some IC clamps and resolved a boost leak, and knock went away and car was running great.

Also, just did my compression test. Looks like the head has to come off 178-100-178-152

 

From the description of the spark plugs initially, the soft plug in the block, the water pump, the spark plugs again...........that tune is off and you are on the verge of a major melt down sooner or later.

 

Hi David and thanks for your reply. The car has been completely retuned since it was put back together with the new motor. i went to one of the most reputable tuners in my area, and I know he wiped out the old tune and started from scratch. I am just very confused about my car... I went to one of the best guys out here for my tune. :/

 

omg another broken m2 cam! how old were these cams??

sry to hear about your problems hope everything works out for you

 

not 100% sure about the M2 cams... Can only guess based on previous ownership.

 

I noticed that you reused the factory cam gears. What timing belt did you use? One for the 4g63 or 4G64? Did you jump a tooth on the gears to make up for the difference in deck height? Generally people use aftermarket gears to either advance or retard the timing depending on the belt that they choose. I figure that you are familiar with that though.

This is the post I was talking about....https://www.evolutionm.net/forums/7678278-post115.html

It seems that it is not necessary, but allows for full mivec control.

 

Plugs melting like that and pushing coolant is a tuning issue. Just because it was tuned by a good shop doesnt mean anything. You could still have injectors that are not flowing properly to some cylinders causing this issue. I would send the injectors out to be cleaned and flow tested, if that shows nothing odd I would then try a new tuner and see how you make out

 

as stated above already, the spark plugs, freeze plugs, headgasket seems like something tune related, or clogged injector. And I see you did mention using the same injectors.

 

i second that, i pretty much had the same problem. ****ty tune, ended up running lean, and boom goes hole in piston.

soon i'll be headin your way sean once i'm done with this build. i hear nothing but good things about your shop.