MORE pics!!!!!


http://i32.photobucket.com/albums/d3...508_182200.jpg



http://i32.photobucket.com/albums/d3...508_183300.jpg

so - what was the problem ?

blew a piston

looks to me like he either threw a rod or overloaded his warp core! :eyetwitch




/subscribed

wrong - it is growing a pineapple out the side of the casting .

After Ray and I taking Phil's engine apart,, I don't see a whole lot of wear. There is wear on the Apex seals, cupping on the sides. This is due to Phil having a blower and a very heavy right foot. JK
Actually most of Phil's issues seem to be a worn out Apex seals. Really didn't like the look of the top edge (housing side) due to the spark plug hole area. Edges were rough on the leading edge of the apex as well. Also a considerable amount of cupping on the apex seal sides that ride in the rotor tip.
I would attribute most of this to being a 2004 and not having the proper oil injection from the OMP.
Side seals had a little carbon blow by on a couple of them on the ends. This would lead me to believe that fitment was not that great.
Oil control rings were very nice! Minimal wear on the edges. That tells me the oil pump is working very well.
I'm a little concerned about some dragging on the pump as it was rotated by hand. It did have a very light wear/scaring on the interior of the faces of rotating group. I have seen worse. I don't believe this will be an issue. But we'll look a little closer at it tomorrow.
Stationary gear bearings had a slight wear area, and I mean slight.
Rotor bearing looked very nice also. Just a slight wear patch. More like a discoloration.
Rotors had a light carbon build up on the faces, nothing to write home to mom about. The rotor sides were very clean!
Cast iron surfaces had light markings from rotor rotation and that was it.
Phil has a very clean engine with only excessive apex seal wear. So whats new?

Flashwing has a few picks to post up as all I had was my phone to use. As you saw in the two posted by Jedi54.
Thanks Jedi,, you tramp!:Eyecrazy:

haha, got your PM. sounds like FUN times man!!!

So what I'm reading is saying that my lack of compression was due to Apex seal wear? You know with the mileage I have on it I would worry about this happening again in a short time. Maybe I need to find that ceramic Apex seal thread and read some more on them. It could also be that now having a Sohn adaptor hooked up that it will help. I may also have to increase the premix I use. Been keeping it at 4oz but if the seals are showing enough wear maybe I should double it.

Ray - Erick, do you see any damage due to overheating? It could be that I'm over sensitave to the over heating problem. While it can be distructive maybe not as bad as I was worried about.

Oh yea, find that piston that Jedi is looking for, you know how it is with those Cali boys :uhh: .

I'll be looking for those other pics that Flashwing has.

I can then blame this whole engine rebuild on Jeff cuz he did not get the Cobb AP soon enough?:lol2: If this engine had over 50,000 miles on it I would not be concerned as then I could just feel that with engineering problems from Mazda and my heavy foot that I got what should be expected. The lack of mileage shows me that there is a very big problem with Mazda engineering due to inadequate oiling. No wonder they are having to rebuild so many engines.

OK as promised I will not bug you but once per day on your progress. My bet would be that the majority of work will take place this weekend. Now this does not mean you can't post progress just that I will not bug you about it (until the next day). Now back to work:whipping:

[QUOTE=Phil's 8;2715079]I can then blame this whole engine rebuild on Jeff cuz he did not get the Cobb AP soon enough?:lol2: If this engine had over 50,000 miles on it I would not be concerned as then I could just feel that with engineering problems from Mazda and my heavy foot that I got what should be expected. The lack of mileage shows me that there is a very big problem with Mazda engineering due to inadequate oiling. No wonder they are having to rebuild so many engines.
[QUOTE]

How many miles have you got?

Remember that i'm doing an engine right now... if they're good goodies pm me please!

exhaust header? what kind of work are you doing?
We have no places here that balance injectors... good 3rd world country...

My car is not a daily driver - just gets used on weekends and a few road races and it gets trailered to the races, 17,500 miles

That sounds great :) . Which header are you getting?

We found here some relations between early mileages and failures, and late mileage failures. If an engine doesn't fail before 40.000km it is then going to last a lot. I'm sure that this is common knowledge here :)
Considering that every header showed approx. the same gains wouldn't working the transitions from the exhaust ports to the flange be worth it and less expensive?

Lucky Phil!

Dam, I forgot about that. I will try and get on it quickly.

Phil--i tried a header--sounds nice.
Differant brands have differant exhaust port match up--most obvious on the siamese port.
One thing you may want to address--all headers that I am aware off do not have the exhaust header support fitting that the oem one has---so there is no way to bolt that thing down to the frame. You may want to fab one.
Apex seal wear out at less than 20K? Damn.
At least you caught it before she blew. So housings are ok ? Great!
OD

I could not believe that it was the way I drove it. It had to be some deficiency and I figured it would be heat. That car has had premix it from the fist week of ownership but it appears that I should have been using more. Since The Vegas Mazda people canceled my warranty I was not able to get all the flashes so that could have contributed to my oiling problem.

The Cobb unit came out too late to help me so oil so far seems to be the problem. I'm sure that Ray has noticed your post on the headers. I was kinda waiting until the RB one came out before I started working on one but now is a good time.

yeah, I don't think the heat killed you on this one, rather the crappy design on the 04's and not getting enough oil into there.
With the Sohn and the AP, I wouldn't worry too much about doubling the pre-mix, you should be fine using the 4ounces.

Glad to see the engine is out and getting the full BHR treatment.

RB header is orderable over the phone now. People are starting to receive the first ones. And they use the same flange as OEM so fitup should be very good.

Picture time! I stopped over at Ray's last night to snap some photos of the rebuild.

http://photos-e.ak.fbcdn.net/photos-...45364_1068.jpg

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http://photos-h.ak.fbcdn.net/photos-...45383_5960.jpg

http://photos-h.ak.fbcdn.net/photos-...45391_8157.jpg

nice pix

It will look much better when repaired and reassembled.:)

As far as the porting goes it's not going to be anything extreme. I'm just going to clean them up a bit. I can see a couple of areas that will allow a little more flow and smoother flow.
Though I would love to give him the Peripheral Port lope.
wap wap wap wap WAAAAP!

unlock the closed PP holes :)
The bigger the hole, the bigger phil's smile!

Hey guys. Do a compression/idle vacuum test on this one before you give it back to Phil please. I'm trying to decide who I want to do my rebuild.