Realgib3 End of the Road Build

[Realgib3]

Well ladies, it's been a long, well documented strugle with this car, but the time has come.
After blowing a head gasket almost exactly a year ago, I've spent the past year trying to
decide the best course of action and have finally decided. I'm returning the car back to
a mild build, with a stock turbo, and will be putting it up for sale after the break-in miles are complete. It will be tough to let it go, but I just have to at this point. With that said, I will not be out of the Mazda game, though I may not have a "Big Build" until late 2016 because of some other projects I'm starting on. Until then, I'll still be tuning and living vicariously through those cars lol.

So for the specs on this final build...

Engine:

Freshly bore/honed 88mm block
Wiseco 88mm Pistons
Manley H-Beams
Mazda OE Bearings
Keyed crank
Stock head
10mm L19's

Power: (or lack thereof)

Rebuilt K04
Catless DP (resonated)
CNT Catback
Garrett FMIC/custom piping
Custom 3" intake
HPFP Internals

Drivetrain/suspension/etc:

Freshly Rebuilt, Gen1 Trans
ACT Streetlight FW w/ Kentucky Clutch full face disk
ISC N1 Coilovers
DM mounts
JBR RSB

-----------------------------------------------

I'll keep pictures coming as I continue assembly this week. Car will have AC and all other amenities back and I'll obviously tune it. I'm not parting it out, so don't bother telling me that.

[rodrigo]

"it ends tonight " famous last words man .....

[TRBLSM]

Sad to see this happen man...but all of your build threads have been more than valuable to the community. Best of luck with the other projects and hopefully the next speed comes back bigger n badder!!

[Realgib3]

Well I lost a whole week last week, not being able to get to the shop, but I finally went back last night.

pulled the cams back out and checked the head stud tq, then put the cams back in and tq them down, put all the timing components in, timed the motor, and started putting on some of the accessories. Should be able to get it off the stand and at least get the clutch/trans bolted up Saturday morning.

[Easter Bunny]

This thread has herpes.

[Realgib3]

More herpes from Saturday @Easter Bunny;

Hoping to find time to put the engine in this week. I have some stupid stuff to finish up in the engine bay like reconnecting my PS lines to the rack and @HOCKEYNUBE; reconnecting the wires he cut, then the engine can go in.

[Easter Bunny]

The flareup is bad...........................

[HOCKEYNUBE]

Originally Posted by Realgib3 Hoping to find time to put the engine in this week. I have some stupid stuff to finish up in the engine bay like reconnecting my PS lines to the rack and @HOCKEYNUBE; reconnecting the wires he cut, then the engine can go in.

Let me know they next time you're going to be out and let me know when the power isn't out this time.... maybe ill bring my stock pump too

and as far as living through other cars... when I run a 10 second pass next year you better actually be there!!! and I may need you to drive it to get it to a 10

[Realgib3]

Got some time last night after work, swapped over all my exhaust mani studs from another head, put the mani,turbo,oil lines,etc etc on, hooked the ps back up at the rack, some other little stuff, then put the motor in. Should be back this weekend to start with wiring, accessories, etc.

First time in 5 years there's a stock turbo mounted in this engine bay. So sad.

[Easter Bunny]

Originally Posted by Realgib3 So sad.

quoted for truth

[HOCKEYNUBE]

Originally Posted by Realgib3 Got some time last night after work, swapped over all my exhaust mani studs from another head, put the mani,turbo,oil lines,etc etc on, hooked the ps back up at the rack, some other little stuff, then put the motor in. Should be back this weekend to start with wiring, accessories, etc. First time in 5 years there's a stock turbo mounted in this engine bay. So sad.

just one step closer to getting to the final goal of the beast that's all....... worth it!

[Realgib3]

Ran into some stupid bullshit issues, then had zero time or motivation to touch this thing, but finally had a while yesterday to make some progress. I can't wait till this is done and out of my life.







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[Realgib3]

Starting to become a car again. Wiring is all redone from when I had the PI/WOT Box/Alternator relocation, Put the interior back in, new charge pipes done, welded up the egr port on the intake mani, etc. couple little things I'm missing (like a fucking Tab gasket) and then it'll be ready to fire up... And get the fuck outa my shop. Finally.







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[Realgib3]

Alright guys, so this car has been "Complete" for about 2 weeks now, but I have yet to be able to start it. Here's a rundown of the issue, but basically... can't get fuel.

Turn key on and ITFP primes (audible)
AP Reads 6 PSI
The end


So on to the things I've tried. There are actually quite a few threads on a similar issue that I've found, but nothing I've found in those has worked.

I've basically made jumper wires to bypass (both individually and all at once in different tests) each of the FP Relays, and the FP resistor balast. All produce the same results, KOEO I here the pump turn on and prime for ~2 sec, only 6 psi pressure builds. Cranking the car like this basically sounds/acts exactly like when you depress both the clutch and throttle all the way to crank the car for a comp check or to prime the oil system on a new build.

I've probably spent 16+ hrs on this issue at this point, gone over all the wiring that was touched from the old PI setup, WOT box, etc, and still exact same issues. I need to get this car going so I can break it in and sell it. Someone please save me.

Oh I also swapped pumps with my 6 and still no dice, 6 runs fine with the 3 pump now, but 3 still no run with the 6 pump.

[Mazdazilla6]

It sounds a bit obvious but all wires that were touched should probably be gone over again. It sounds like one is shorting and not getting proper voltage to the pump. Have you done any testing with a multimeter?

[Realgib3]

Originally Posted by Mazdazilla6 It sounds a bit obvious but all wires that were touched should probably be gone over again. It sounds like one is shorting and not getting proper voltage to the pump. Have you done any testing with a multimeter?

Yep I've gotta assume something got fucked when the PI wiring was removed, but each of those (only 4 wires) has been looked over multiple times and are all soldered and wrapped up nicely.

I'm also reading ~11.5v+ at the corect pin on the ITFP plug, then voltage jumps for ~2 sec when you go to KOEO, then back to 0, again, on the proper pin. This is basically showing that the "Priming" procedure is happening correctly from a voltage standpoint.

It's just crazy that even with the feed line disconnected from the HPFP up in the engine bay, just trying to get gas to flow into a cup... still not enough pressure to even make it there.

[Easter Bunny]

Kink in a line somewhere?

[Realgib3]

Originally Posted by Easter Bunny Kink in a line somewhere?

Yep that seems to be the consensus from everyone today is an issue with the line, which is completely believable since I had then ripped outa the car before. Unfortunately won't know till Tuesday night.

[Easter Bunny]

I hope I'm wrong but I have to ask


Are.you sure there is gas in the tank?

[Realgib3]

Originally Posted by Easter Bunny I hope I'm wrong but I have to ask Are.you sure there is gas in the tank?

lol. I've done some dumb shit, but yes there's over half a tank.

[sheston]

Could it have gummed up enough to cause this by sitting so long?

[Realgib3]

Alright looked at it more today.

Started at the ITFP and slowly connected more and more lines until we stopped seeing fuel. Narrowed it down to something at the HPFP.

Basically, fuel is getting to the HPFP, but none is getting through it to the rail. Took the pump out and at first glance everything looks fine. The issue is fuel will go from the feed line, into the pump, then straight back out the "yellow clip" side nipple of the pump, but no fuel will come out of the pump toward the hard line to the rail.

gay.

[Yatta]

Originally Posted by Realgib3 Alright looked at it more today. Started at the ITFP and slowly connected more and more lines until we stopped seeing fuel. Narrowed it down to something at the HPFP. Basically, fuel is getting to the HPFP, but none is getting through it to the rail. Took the pump out and at first glance everything looks fine. The issue is fuel will go from the feed line, into the pump, then straight back out the "yellow clip" side nipple of the pump, but no fuel will come out of the pump toward the hard line to the rail. gay.

relief valve stuck?

[Realgib3]

Originally Posted by Yatta relief valve stuck?

Spill Valve?

And there's for sure a possibility of issues with the CDFP, which I'll be taking apart tonight since I now know where the fuel is stopping.

I'm just trying to wrap my head around how we typically get fuel to the rail by just turning KOEO a few times, without the CDFP even pumping? Like I just need to see on paper what path that ~50psi of fuel takes to get through the CDFP to the rail, before I even turn the car over.

[Yatta]

Originally Posted by Realgib3 Spill Valve? And there's for sure a possibility of issues with the CDFP, which I'll be taking apart tonight since I now know where the fuel is stopping. I'm just trying to wrap my head around how we typically get fuel to the rail by just turning KOEO a few times, without the CDFP even pumping? Like I just need to see on paper what path that ~50psi of fuel takes to get through the CDFP to the rail, before I even turn the car over.

yes, sorry, I get the two confused, but would check the valve on the CDFP, its designed to pass fuel...

[Realgib3]

So does anyone have any idea what the crack pressure of the CV inside this fitting is? I've narrowed everything down to fuel stopping at this fitting, not being able to flow through the pump to the hardline, then to the rail. There's a small check ball at the tip of the fitting that can be pressed in with no effort, so that's not the issue. I'm assuming there's a check valve further within the fitting though, that is keeping fuel from flowing through for some reason. All I know is I can't blow through the fitting right now and I can't get fuel to flow through it either. The rest of the pump is very clean and seems to be functioning properly.

[Mazdazilla6]

I know this is WAYYY off topic (but it's your build thread), but I saw somewhere that you're running RD's clutch kit. Can't really find to much on it but it seems like a hell of deal.

Also did you measure the pressure from the itfp right before the hpfp?

[anavrinIV]

since you swapped pumps and both run fine in one car and both don't solve the issue with your 3 I'm guessing it's past that. hardline clogged?

[sheston]

So with the pump off, you can do KOEO and get fuel out the hard line? Just adding to ^^ @anavrinIV;

[Realgib3]

Originally Posted by sheston So with the pump off, you can do KOEO and get fuel out the hard line? Just adding to ^^ @anavrinIV;

Nope, the hardline comes after the HPFP, so I get fuel to the HPFP from the tank, but nothing makes it past the check valve in the outlet of the pump.

I'll be checking the pressure coming from the tank next. If that's low though, I have no clue where I'll look next as far as issues go.

[Easter Bunny]

Could the filter sock be full of shit and gummed up from sitting

[Realgib3]

Originally Posted by Easter Bunny Could the filter sock be full of shit and gummed up from sitting

I kept the sock with the pumps when I switched them, cuz I was thinking the same thing. Only thing that stayed between them was the actual basket and top hat assembly. Maybe a hole in the actual pickup tube in the basket? If it turns out to be low fuel pressure issue, then something like that, creating an internal leak basically, could be the problem.

I just know it's an hour drive each way to the shop and I'm tired of driving out there, especially in the winter, to get fucking no where.

[Easter Bunny]

damn thats inconvenient

[Realgib3]

Well it runs. What a stupid fucking issue. I'm still debating on whether I want to divulge ALL the issues that have gone on with this build in the last year, but for now I'll wait and just be happy it runs.

MAF is unplugged since I didn't have my laptop with me to flash a basemap on the car for 3" MAF and 50/50. Other than that, it runs well, no leaks yet. Still have a lot of little stuff to button up, including putting a wiper motor back in, putting the bumper back on, etc, but I should have it ready and driving in a week or so.

YouTube Short

YouTube Short

[Easter Bunny]

I need to know.

[Realgib3]

Originally Posted by Easter Bunny I need to know.

Well I will tell you the fueling issue was an o-ring that was removed by a friend, when he swapped his stock pump for my aftermarket one. One little fucking o-ring that wouldn't allow pressure to build.

[Easter Bunny]

Where was the fuel going?

[Realgib3]

Originally Posted by Easter Bunny Where was the fuel going?

Back into the basket. It's one of the o-rings on the regulator.

[TRBLSM]

@Realgib3; sent you a PM


Tapatorque steering

[Cmfk]

Seems legit haha atleast it idles now

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