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I have cleaned out the tank with the set of treatments from POR15 and then finally painted the tank. Also cleaned underneath the back section of the body with all the rear suspension an subframe out, treated the surface rust with a CRC rust converter and then use spray can underseal to seal it. Next step is to one by one clean, paint and replace the bushes on the diff and each suspension arm and bolt them into the car.
Here is the diff after a clean up, new powerflex bushes and painted mounting beams. I have decided to keep AYC as there were no problems with it when the car was running before I pulled it apart so untill/if I have issues with it im going to leave it as it is. Next is to clean up and paint the subframe black.
Not much to report, just slowly going through the rear suspension, cleaning, painting it black and replacing all the rubbers with powerflex bushes and hardrace ball joints. Only the swaybar and the lower suspension arm to go.
Quality seems good and I have no idea with longevity because I have not driven the car with them and it would take a while to know if they will go the distance or not. The main reason I went with them was because it was really the only replacement ball joint I could find as the standard ones do not come separate to the suspension arms.
I have wired up the fuel pump to mostly bypass the double relay and resistor system. I have run a wire from the battery positive to the input of the standard fuel pump relay 1 and then from that relay straight to the fuel pump positive and then I ran a separate earth wire as well. The coil side of the relay has been left so it wall still be switched by the ecu. I will heat shrink the connectors at the relay. I have also water blasted and undersealed the rear wheel arches.
I have cleaned up the wiring by taking off all the old conduit that was crumbling and broken and put black braided self closing wire protection on. It didnt come out looking like I had hoped but it is ok. I also made up a battery tray to move the battery back beside the fuse box to create room to place the pod filter where the battery normally is behind the front left head light. Its not in this picture but i also mounted the fuse box that is on the positive battery terminal next to the large fuse box due to the cables not being long enough to reach to the new battery location. I am using a DIN44MF battery as well because it is smaller and fits in the new spot.
Last edited by kylefowlie; Oct 18, 2020 at 03:57 AM.
So I took the car in for a tune just to get it up and running. The place only has a two wheel roller dyno so they just did a road tune and it is really safe so 9psi and boost and im guessing not much timing because it doesnt make much power and about a 5k rpm limit. Im happy with that because thats all I asked for just so it can be driven and run in and sort out teething issues like oil leaks ect. I have bought a set of BC gold coilovers to go in. I need to get the car on a hoist to install them and have a look as at a few issues like some suspension sounding knocks, exhaust clearance and I think there is a small oil from the sump side of the turbo drain. Cant wait to get that stuff done and get it off for a power tune after that.
So the car went in for a proper tune and made 325KW on pump gas (RON98). The tuner had no issues really except for a tiny fuel leak through the weld where the AN fitting was welded onto the stock fuel rail and the idle was doing some funny things for him. I have got a new idle control valve and will fit that at some point but is not urgent as it still idles ok, just a bit high on the odd occasion. Next is to buy some brembos of the later evos and rebuild, paint and fit them. The problem with this is the car has the stock wheels so to fit the brembos it will be a huge cost due to the upgrades that will all have to be done at once (brakes, rims, tyres). This is something that I hope to start doing Jan Feb next year. Then it will be driveshaft hoops as they are needed to get a cert to get the car road legal here then finally it will be all cosmetic stuff inside and out. Still a long way and a lot of money to go till I am happy with the car but it is good to get the tune all done.
Evo now has brembos fitted that I painted white, may or may not have been a bad decision with how easy white will look dirty with brake dust but I guess time will tell. I also bought some evo 5 wheels to clear the brakes. Next up is driveshaft hoops. I have asked a question of them in another thread I started so if anyone has fitted hoops to an evo 4 5 6 please have a look at that thread and help me out.
