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Curtís Gr8t 8 Turbo Build

Old 01-06-2019, 06:29 PM
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Progress update: Engine prep & re-installation into the engine bay...

I know this is old hat for some, but since I could find no good best practice detail for re-installing the engine... I'll provide what worked well for me.

First time engine re-install...multiple unsuccessful attempts mating the engine to the trans while suspended from the crane. I found the engine too heavy while suspended to have good precision & range of motion to "level & mate" to the trans. (unless perhaps you have a few other pairs of hands. I did not) Worked at it this way too long...

Slept on it... & thought to use the crane only to position the engine in the bay onto a dolly, which would level & provide lateral movement of the engine. Then used a floor jack to adjust the height of the trans to "mate" the two. Worked perfectly...mated in ~ 5 min. by this method.


Thermal cover delivered & installed. Engine ready for re-install.



Trans bell housing on flr jack for adjust-ability



Dolly used to level and "mate" the engine to the trans...



...going in.



I
I
V


Engine on dolly (built up a bit) ...and trans on flr jack for leveling to proper height...



Mission accomplished: engine re-installed, mated & bolted up to the trans.

Last edited by jcbrx8; 01-07-2019 at 06:30 AM.
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Old 01-06-2019, 07:02 PM
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Great you got it in ok but bummer it took so long.

Too late now ...but i've done this a lot of times............
1/Jack geabox up as high as it will go ..then let it down maybe 10mm
2/Set engine at approx. same angle as gearbox by adjusting where you lift it from .
3/lift engine into hole lower then push rearward , lower more and push rearward etc etc
4/when at same height,angle and within 2" of each other ...slide her right in there .
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Old 01-06-2019, 09:04 PM
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Originally Posted by Brettus View Post
Great you got it in ok but bummer it took so long.

Too late now ...but i've done this a lot of times............
1/Jack geabox up as high as it will go ..then let it down maybe 10mm
2/Set engine at approx. same angle as gearbox by adjusting where you lift it from .
3/lift engine into hole lower then push rearward , lower more and push rearward etc etc
4/when at same height,angle and within 2" of each other ...slide her right in there .
Brett, Thanks. I know I c/h asked... but it was a learning experience I won't soon forget.

I found it challenging hanging the engine at the just the right angle, and based on the position of the hangers it twisted as well. Once sat on the dolly & leveled... piece of cake.

Holiday's over and work is a beast right now . So, it'll likely be a couple of weeks before she's running again. Based on porting & a sealed e-mani I'm anticipating >10-15% improved spool and torque across the range.

Last edited by jcbrx8; 01-06-2019 at 11:06 PM.
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Old 01-06-2019, 10:58 PM
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wow,

great job. food for thought.

beers
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Old 01-07-2019, 12:23 AM
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Originally Posted by swoope View Post
if it helps, and i know it doesnt. i am in the same boat, but i managed to do it without boost..
not sure how i am going to proceed. beers
Originally Posted by swoope View Post
wow,. great job. food for thought. beers
Swoope, Do eet! Get her rolling again.
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Old 01-07-2019, 08:01 AM
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Getting the engine and transmission together without damaging the pilot bearing is so hard using this method. I have been lucky a few times with everything going together. I have also struggled for hours only to take it all back out again so I feel your pain. You haven't lived until you installed an engine with a jack, hoist, and wood blocks....
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Old 01-07-2019, 08:16 AM
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Originally Posted by strokercharged95gt View Post
Getting the engine and transmission together without damaging the pilot bearing is so hard using this method. I have been lucky a few times with everything going together. I have also struggled for hours only to take it all back out again so I feel your pain. You haven't lived until you installed an engine with a jack, hoist, and wood blocks....
Truth...
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Old 01-12-2019, 09:09 AM
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Small, but important update: I'll just call this "head-space"

Went out to make some progress on the build not in a good "head-space", i.e. not thinking clearly, creatively, patiently. Lesson learned. Task was simple: re-attach oil coolers feed & return lines to the timing cover and oil filter mount, respectively. Result:
- Stripped the oil filter pedestal banjo bolt threads
- Had to remove the filter mount (the rear bolt is a bear to reach)
- Re-tapped the threads (note; It's a 18x1.5mm thread size for anyone interested)
- Re-mounted the pedestal
- ~ A week later finally finished reattaching the oil cooler lines
Also reattached the AC compressor

Perhaps not an issue for experienced mechanics, but for novices, e.g. myself, avoid wrenching when not "clear". Some finished pics.



The culprit oil mount banjo bolt threads. Difficult positioning of rear mount bolt (sandwiched in a tight space & under the hard black trans line)



Oil cooler return line finally in....after another trip to Lowes to replace the front M8x1.25 mounting bolt which began acting squirrely.



AC compressor in... and oil coolers feed line on the right.



Driver side coming together...



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Old 01-12-2019, 06:18 PM
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Bugger re the pedestal ..... next time (hopefully not) ..... put that tube on before you fit the engine.
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Old 01-12-2019, 09:07 PM
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Originally Posted by Brettus View Post
Bugger re the pedestal ..... next time (hopefully not) ..... put that tube on before you fit the engine.
Will do.
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Old 01-12-2019, 09:25 PM
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Progress update: Misc progress... installed:
- oil filter reloc head unit
- e-shaft pulleys & belts
- new coolant hoses around
- ignition coils & wires
- starter & power cabling
- turbo oil drain
- DP w/O2 sensor & WG
- Successful pressure test of fuel rails & injectors



Pulleys and belts...



New coolant hoses around...



DP & WG (old pic...oil pan is not yet installed)



Last edited by jcbrx8; 01-14-2019 at 10:43 AM.
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Old 01-13-2019, 02:00 PM
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nice build
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Old 01-13-2019, 05:01 PM
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jcbrx8: Where did you get your coolant hose kit? And what's the reason for the earlier version / later version stickers? Series 1 RX-8 vs. series 2?
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Old 01-13-2019, 09:52 PM
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Originally Posted by yomomspimp06 View Post
nice build
Thanks! It's been quite the journey...
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Old 01-13-2019, 10:00 PM
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Originally Posted by TomD_Cincy View Post
jcbrx8: Where did you get your coolant hose kit? And what's the reason for the earlier version / later version stickers? Series 1 RX-8 vs. series 2?
here , RX8 versions...
Amazon Amazon

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Old 01-14-2019, 11:50 AM
  #166  
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Progress update: Installed...
- Oil fill reservoir w/ Intake valve solenoid connectors
- UIM w/ vac & charge hoses terminated at rear
- Modified compressor intake section
- Motor mounts
- Oil pick up & pan





Oil fill reservoir w/ LIM intake valve solenoid connectors



UIM.......(w/ vac & charge hoses terminated at rear)




Cut 1/4" off compressor intake section. Crazy simplified installation. Unconcerned about the clamping nubs...when installed, space is so tight...it's not going anywhere.




Driver side motor mount w/ compressor intake fitted



Passenger motor mount...



Prepped sump area, and re-installed oil pick up



Oil pan cleaned, prep'd (ultra grey) & installed. Turbo drain fitted.

Last edited by jcbrx8; 01-14-2019 at 11:56 AM.
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Old 01-15-2019, 01:11 AM
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Progress update: Installed...
- Throttle body
- Oil filter reloc remote unit
- Turbo oil feed
- Remaining wiring harness connections
- Front crash bar & IC
- CAI & turbo charge sections
- BOV & recirc.

Vac hoses:
- oil filler
- OMP
- Jet Air

Control hoses
- BOV
- WG & EBC controller

- swapped in a 1.5# WG spring.

Yet need to install the midpipe, add fluids, dbl-ck all connections, and she'll be ready to fire up tomorrow.



Charge to IC section



Decided to temporarily remount my IC in the front mount configuration. Before summer I'll investigate changing to a v-mount config.



Couple finished bay pics...



...



IC to engine bay section.

Last edited by jcbrx8; 01-15-2019 at 10:37 AM.
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Old 01-15-2019, 11:34 AM
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Looks good man, just a quick thought (hard to tell from the angle of the picture), but will you be able to fit your strut brace back on with the oil filter and catch can located there?
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Old 01-15-2019, 12:00 PM
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Originally Posted by RotaryMachineRx View Post
Looks good man, just a quick thought (hard to tell from the angle of the picture), but will you be able to fit your strut brace back on with the oil filter and catch can located there?
RMRx - Thanks! Good eye...but yes the brace just fits between the filter & catch can.

edit: couple of pics from first install:



Strut brace positioning...fits between the filter and catch can.



...
.
.

Last edited by jcbrx8; 01-31-2019 at 09:05 AM.
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Old 01-20-2019, 01:38 PM
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Progress Update:
Well, push started her, and drove around the block keeping ~3k rpm to keep from dying. ~7-10 min in I saw steam from the engine bay (the hood was off), and coolant temp rose rapidly, hit 230 for 1-2 sec and dropped. I immediately turned off the engine, and pulled over. Allowed it to cool ~15min, added coolant, push started again and drove back to the house...~a block.

I presumed the coolant hose on the rear iron had come off based on where I saw steam. So pulled the UIM & oil filler reservoir, and found the coolant hose secure. Hmm... Searched for other sources of coolant leak, and found none. Reassembled everything, refilled temporarily w/water, and immediately saw the problem: water running from sm port on bottom of trans bell housing. So, clearly its a coolant issue w/in the engine.

After some thought ... I suspect a cracked front iron. Through various research I understood that the irons could sustain torque well beyond 50 ftlb. Therefore, I torqued to ~46 ftlb. However, when torquing one stud I felt a "release". I think now that m/h been my front iron giving way. Good decision to purchase studs, poor decision to torque into the 40s ftlbs.

So, the engines coming out again, to inspect, validate & correct the problem. Disappointed, but not discouraged... learning a lot...more to come.

Last edited by jcbrx8; 02-16-2019 at 05:23 AM.
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Old 01-20-2019, 03:08 PM
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Damn ...I know that feeling too well . At least you are learning heaps as you go.
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Old 01-20-2019, 09:02 PM
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What are the studs supposed to be have torqued to that 45 was too much?
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Old 01-21-2019, 08:23 AM
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They warn you when installing the studs that an iron can crack with the higher torque numbers. That really sucks.

I run 30 ft/lbs on the stock bolts then give everyone of them an extra 1-2 ft/lbs to convince myself my motor is stronger....

If you want a free front plate with 100k miles on it let me know and I will send it to your for shipping costs only. It just sits in the corner collecting dust. Never been modified... I can send pics if you like.
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Old 01-21-2019, 09:33 AM
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Originally Posted by strokercharged95gt View Post
They warn you when installing the studs that an iron can crack with the higher torque numbers. That really sucks.

I run 30 ft/lbs on the stock bolts then give everyone of them an extra 1-2 ft/lbs to convince myself my motor is stronger....

If you want a free front plate with 100k miles on it let me know and I will send it to your for shipping costs only. It just sits in the corner collecting dust. Never been modified... I can send pics if you like.
Stroker, Thanks. I'll IM you.
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Old 01-21-2019, 09:55 AM
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Originally Posted by Brettus View Post
Damn ...I know that feeling too well . At least you are learning heaps as you go.
Brettus, Yeah...tough h/b so close. But I have learned so much..., have outfitted my "home shop", and am hoping I can reuse most of the consumables, e.g. rotor & water seals, etc.

I guess I'm a cat guy... She's definitely making me work for it...

Jack: Greg, how come you don't like cats?
Greg: I don't not like cats. I-I just-- I just prefer dogs. I mean, I'm just more of a dog kind of, you know--Come home, wagging their little tails, happy to see you kind of--
Jack: You need that assurance? You prefer an emotionally shallow animal?
Greg: I--
Jack: You see, Greg, when you yell at a dog, his tail will go between his legs and cover his genitals, his ears will go down. A dog is very easy to break, but cats make you work for their affection. They don't sell out the way dogs do.
- Meet the Parents

btw...I'm actually a dog guy. We love our vizsla, Koda.

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