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lukeoly's turbo bandwagon GEN3 Wagon


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#161 Lukeoly

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Posted 03 October 2014 - 11:37 AM

UPDATE!

 

It's been way too long since my last update. I've been super busy with work and family stuff and haven't had much good news to share.

 

The weekend after we got the engine in; Cam, Lachy and Morgan came over with the plan of getting it going.

We started out with something simple; bleeding the clutch. This turned into half the morning as it simply refused to bleed. We came to the unfortunate conclusion that the master cylinder is toast  :angry:

 

bpl3xiLl.jpg

 

It's all the little things with these conversions that take the time. Cam was able to bring Geoff's (aka Guffry - thanks mate) MY02 Bugeye along as a point of reference. This turned out to be super helpful for things like vac lines wiring routing!

 

NBwRXAHl.jpg

 

eaWKF3sl.jpg

 

Unfortunately the car was having trouble starting. We were getting a battery draw light which we thought may be the cause but after swapping out the alternator with the Liberty one the light went away - WRX Alt looks like its cactus. But the car still wouldn't start  :(

YDgfpWDl.jpg

 

After doing some troubleshooting we decided to call it a day. I suspected that there could be pin location differences between the JDM WRX wiring and the AUDM WRX manifold wiring.

 

I gave Miles at AM Auto a call for some insight and after some comparing of wiring diagrams, Miles was able to confirm that besides the lack of AVCS (on the '01 AUDM WRX manifold), all other wiring matched up. While this was a relief of some sorts, it still didn't shed any light on why the car wouldn't start.

 

Last weekend I set some time aside to do some more troubleshooting and go over anything I'd missed or connected incorrectly.

I managed to get the car started on starter spray which proved the engine was getting spark; it also meant that the cam and crank sensors were working properly (something I had suspected to be the cause). I also double checked fuel lines at both the tank and the manifold to make sure the send and return lines weren't mixed up; they weren't. 

 

Miles also recommended checking the injector pulse. This can be done quite easily (and cheaply) with a 12V LED by probing the injector connector. I picked up a 12V LED from Jaycar for $3 which worked perfectly. This ruled out injectors too!

 

It's hard to pinpoint what the issue was but I have a feeling it was a connector at the back of the under-dash fuse box. It was plugged in but I don't think it was seated properly. There was a few other little fixes I found, but I don't think they were the causing the issue.

 

One thing I'm glad I found was this bent pin on the MAF:

Rsbwlcxl.jpg

 

I'm sure I would have assumed the sensor was dead when it threw a code I hadn't found this. The pin was easily straightened and plugged back in.

 

 

The exciting news is it runs!

I didn't have it running for long as the power steering pump is without lines and fluid but it was running well  :yahoo:

 

The only things missing now are a GD steering rack, pump, lines and a clutch master. I can then take it to get the exhaust modified to fit!


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#162 duncanm

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Posted 03 October 2014 - 11:44 AM

woohoo! Well done. Sounds like a week of serious frustration and head scratching

#163 Lukeoly

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Posted 03 October 2014 - 11:51 AM

It really was mate. I kept telling myself it had to be something simple but as you know; when a car's been this much apart it can be a hundred different things.


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#164 Barbbachello

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Posted 03 October 2014 - 11:55 AM

Nice work. Keen for some startup vids
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#165 Lukeoly

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Posted 03 October 2014 - 11:57 AM

I thought about posting the startup vid I took. But it's half dark and the poor power steering pump starts getting cranky

ndvgQm2.jpg


#166 Morgan

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Posted 03 October 2014 - 12:39 PM

Such good news that it's running now with a bit of extra fuel.  

 

Keen to see this thing mooooove!

 

 

Keen for some startup vids
 

 

What about some startup attempts?

 

I have about 41 of them :P

 

http://vid645.photob...zps4epgqzq8.mp4


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#167 Lukeoly

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Posted 03 October 2014 - 12:42 PM

Haha. Unimpressed Cam is unimpressed

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#168 Lukeoly

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Posted 03 October 2014 - 02:10 PM


 
 
Please excuse the testy popping brother cameraman LOL


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#169 Beckers

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Posted 03 October 2014 - 06:28 PM

Nice job getting it started, must be such a good feeling !!



#170 LPM_B4

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Posted 03 October 2014 - 11:22 PM

Awesome Luke glad its finally going mate :)

Hopefully once you piece together some final bits you'll be able to drive it 

Cam will be happy when he sees this 



#171 STI.PSI

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Posted 04 October 2014 - 12:06 AM

Good job mate, its a nice feeling when it starts after its together.!!
Gen3 + 2.2 + 35R + 6spd = FTW

#172 Guest_KONG_*

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Posted 04 October 2014 - 08:47 AM

The plug behind the fuse box lol.

I think it gets everyone. It shouldn't sit like that.... But it does apparently.

Great work mate. Bloody bent MAF pin.

#173 Adam

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Posted 04 October 2014 - 08:52 AM

NICE


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#174 Cam.

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Posted 04 October 2014 - 04:46 PM

Halle-freaking-lujah. One job Luke :P

Glad it's sorted. Time for the little bits!

P.S that bent pin is for your IACV, Not MAF.


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#175 Lukeoly

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Posted 04 October 2014 - 07:50 PM

One job aye. Haha.
I couldn't remember which one it was from the pic

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#176 Lukeoly

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Posted 04 January 2015 - 12:52 PM

Update time!
 
It's been far too long since my last update.
At first it was lack of budget, then it was lack of time. As I'm sure with most of the people on here, I wanted to squeeze in as much car time as I could through the break. While I didn't get as much time as I would have liked, I did manage to get the car mostly done.
 
First on the agenda was to head down to Ichiban and pickup some goodies.
I snapped up the Version 5 STi steering rack they had for sale as well as a GD power steering pump and lines. I also grabbed a WRX clutch master cylinder as the Liberty one was toast.
 
The clutch master was fairly straightforward. The '06 WRX TMIC gives plenty of clearance.
 
Out with the old:
pe2Muudl.jpg
 
In with the new:
cGFIPyol.jpg
 
The steering rack install was also a pretty quick job. Morgan came around to lend a hand and bring some fresh enthusiasm to the project. It was all going well until we started to route the lines. The GC8 rack has uses a narrow angle for the lines and the GD uses a wider angle. This proved to be a huge issue as there as space is quite limited and it was almost impossible to get the GD lines into to rack. I managed to get them in with a slight bend here and there but I'd like to get some opinions regarding how close the lines come to the uppipe and the crossmember in places.
 
I've pinched some comparison pics from eBay (GC8 on the left, GD on the right):
4jpFdaml.jpg
 
I can't think of a car that used the GD style remote reservoir and the GC8 narrow rack but if someone knows of one, I'm all ears. Otherwise I may end up getting the gc8 rack end hard lines put onto the GD lines for peace of mind and perfect fitment.
 
I also had a bit of trouble mounting the power steering pump :-(
The pump bracket fouled on the coolant crossover pipe. I ended up having to clearance it a little to make it fit (it's the little year variations like this that have made the conversion a bit frustrating. All of which would be avoided by using a complete front cut like a smart person).
 
One thing I've learned (the hard way) in this project is that you shouldn't work on something if you're tired, cranky or both. Sometimes it can't be avoided but when you don't have to get it finished (to get to work the next day for example) it's better to walk away and clear your head.
 
I was getting a little frustrated fitting the PS pump when I was having clearance issues. It was hot and I was tired. Whilst struggling with the pump and trying the line up the mounting holes, I lent on the top radiator hose without realising and managed to snap the top radiator hose fitting straight off the top tank!
I could have cried!
 
At that moment I just had to walk away. With the car so close to being drivable it kills me that there's now something else stopping it from being drivable.
 
At first I was tempted to go out a source another cheap replacement but I'm now thinking it's worth spending the extra money to get a new alloy unit.
 
I'm open to suggestions at this point, but I'm leaning towards a Golpher alloy rad from eBay. I've heard mixed reviews but the bad reviews seem to be about eBay rads in general and not Golpher units specifically.
Does anybody have some experience they'd like to share?

ndvgQm2.jpg


#177 Morgan

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Posted 04 January 2015 - 01:20 PM

So happy you got that PS line in! What a mission...

 

She's so close, man. Can't wait to see it on the road :)


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#178 Beckers

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Posted 15 March 2015 - 08:44 PM

You got any new updates for us Luke ???



#179 Matt

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Posted 15 March 2015 - 08:56 PM

I have the same ps setup in the gen3...and in the rs now aswell...didnt need to bend the rs ones...just undid the little bracket holding the lines together and put the pipes on individually.....then moved that bracket to where itd fit which was only a few mm further up

No clearance issues at all?

And when i put a gd rack in later all ill have to do is undo them again and do the same

#180 Lukeoly

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Posted 15 March 2015 - 09:12 PM

Hmm, I might have to re-visit the lines for peace of mind.
I've been so slack on the updates. I have a huge update to add but I've been absolutely flat out with work.
I'm gonna try to write out an update this week. Stay tuned ;-)

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