Another package - fresh DBA rotors:


Not sure where the rears are...;-)

 

Few more parts showed up:

New main bolts (OEM):


Test fitting:


Front (oil) plate hardware...ours is missing:


More cleaning:


More test fitting (more entertainment than a Rubiks cube!):


More test fitting (What does this do Dad?):


Our 'replacement' camshafts arrived...these are one step over stock and hopefully give a bump...GSC model S1:


Cam card:


And requisite valvetrain support - no tick lifters (no lash caps!!!):


Latest beehive springs with Ti retainers (not the best experience with Ti on a street car - manufacturers have told me they are consumable parts):


Full OEM gasket kit (for a later model...hopefully most apply):


Mahle pistons are set to arrive at the beginning of the year along with new valves and locks...

 

Few more parts arrived...this time for UAE. Not sure why they have Evo V OEM parts in UAE...but we sure did get hit on import tax! That was not planned for...nearly $180 extra on 4 wheel bearings. Learned our lesson!


And


Will put some time in on another project so we can transfer the jackstands to this car and start disassembly! Someone is getting anxious...

 

Finally - class has begun!

Discussed how to jack stand a car...not unlike a Subaru STI! Someone amazed at 100 pounds could lift ~2500 pound car:


Loves the impact tool (lefty loosey):


Off with the caliper (the bolts were tight!):


And axle - plan to install new boots and regrease...first for both of us!:


Day 1 complete...


Nah, this won't be loud!...Actually it is Japan and German certified so likely it will be reasonable in sound (Fijisubo RC1A SS 3 in system):


Contacted Summit about our Manley exhaust valves (ours were burned)...Another 2 weeks awaiting shipping (been 6 already). They offered $25 concession - acceptable. The head shop is closed now anyway.

 

Success! Ready to ship for rebuilding/refinishing...

 

Christmas came a day later...box from STM full of goodies.

New sensors (original crank position indicator was looking a bit crusty):


More pieces to the puzzle - transfer case bolts - new OEM!:


Dust covers and more correct hardware:


And some small victories - new pedal pads for fresher interior and simple install for the lady:



And to keep the femine side happy - a bit of arm twisting to add some color to the auto:


I will try to keep it to a minimum! (we did need new ones versus the three varieties before)

 

Christmas came again...6 weeks to arrival...Mahle forged pistons...and a simple installer (bit of a splurge):


Piston skirt coating and overall phosphate covering:


Few specs:


Nice improvement on the OEM injector flows - a good baseline to start from. We expect to require slightly larger eventually. Wonder if #1 may have contributed to the previous engine failure?:


At least they look the part:


And some progress...off with the old arm - can't believe it is aluminum under that filth:

 

Nice comparison - new parts are so nice:


Assistant learned about levers - 8 inch ratchet doesn't quite have the same torque as an 18 inch breaker bar. She pulled the bolts herself as we removed the seat for further cleaning:


Another easy kill - polished the Mishimotor radiator - a bit of brightness to the dim engine bay:


Fresh O2 sensor...boy was it tight!:


Hmm...a rather quick de-mod from a previous owner:


Following a good cleaning - tomorrow may allow us to install some new parts...

 

All clean...hard to notice admittedly.


First step...cleaning bolts the unpleasant way...manual style since unable to find the drill attachment - bummer:


New suspension arm in and new OEM wheel bearing being secured:


A nice improvement, she things after the fresh DBA rotor, Stop Tech brake line and of course the purple lug nuts:


A few surprises...Hmm...what happened here?


Don't mind the grass - the metal chunks are a bit of indicator on past engine failure:


Suppose this could be patched up...the rest of the system doesn't look much better though after a closer inspection...

 

Exhaust: we were hoping to use the exisiting. It is listed as a quiet system and the large tip is fun. We also found out it is not a full 3 inch, but 2.75 in places so inevitably we will be looking for a 3 inch system. Hopefully avoid excess noise...another expense not planned. Quite a selection out there though...even for a 22 year old car!

Progress...

Installation of new ARP 2000 rod bolts to the Oliver rods and test fitting set of King rod bearings:



Also pulled the driver seat for some cleaning...quite good condition. Some 'fur' from abrasion...interestingly a fabric shaver/saver worked like a champ in removing the wear:


And several applications of carpet cleaner to pull the soiling up...3 times and still giving off brown stuff:


Tomorrow we will work on the other front corner...

 

Temps are in the 20's now...chilly in the garage even with the heaters!

Received more hardware to attempt to piece things back together. Found enough bolts for the water pump and the oil filter adapter installs..timing cover fasteners appear to be accounted for:


Pre-tear down of the left front:


Inwork! All fell apart nicely especially since we know how to do it now:


Still contemplating the exhaust - likley update the turbo 'elbow' to 3 inch size, similar 'down-pipe' and cat back. HKS Silent Power seems to be the winner - even though we will have to cut the 2.75 flange off to remove that restriction. Unfortunate the existing system won't at least get us started...

 

Wooauu,,
Beautiful work.. Fortunately there are people like you to rehabilitate these cars so that they don’t end up breaking up..

Good continuation I can’t wait to see the final result.

 

MEvo_IX: Appreciate the comments. Admittedly, we are doing a very minimal restoration while getting it roadworthy - still a bit of a challenge overseas. We have spent quite a bit of time/money fixing other folks 'improvements.' We hope to keep it semi stock and enjoy it as intended. If anything like my STI, great cars all around.

Started to look at the rear...


This fuel filler shield is in surprisingly good shape according to these forums:


We ordered new upper arms for the rear - still available new.

 

Warmed the garage a bit to do some more education...

The assistant installed fresh suspension arm, wheel bearing, and rotor...all by herself:



The rotor was a bit of a struggle - rather hefty:


Then moved to the 'bullet'...checked ring gaps on the Mahle provided rings:


She was a bit put off at the tedious process of gap checking 16 rings (2 compression/2 oil scrapers per piston). She should count her blessings compared to a V8...

With the results:


Researching if we need to buy a ring grinder...good fun though with 29 degree temps and no skiing allowed!

 

Started disassembly of the rear...bit more complicated with 4 suspension arms per side and the fun parking drum brake setup. Apparently, the wheel bearings are known to fuse into the housing too...cross our fingers.

We did use a ball joint press to free the top arm...boy did it make a pop - bit startling:


And the parking brake fun - always fun figuring out where all the springs/bar/'nails' fit: