Jesse888 Forged/stroker turbo ek9


It was defo the turbo making the smoke ive been mentioning in previous posts aswell. The clamps holding the exhaust side together where caked in a thin layer of oil. So i can stop worrying about the engine as i know its defo turbo seals.
 
Turbo leaking is a feed and or return issue as the oil seal is a metal piston ring and will generally stop leaking when these issues are fixed.

Also could be excessive crankcase pressure or to much oil in your sump blocking return.
 
MadM1ke87 said:
Turbo leaking is a feed and or return issue as the oil seal is a metal piston ring and will generally stop leaking when these issues are fixed.

Also could be excessive crankcase pressure or to much oil in your sump blocking return.
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Its the return line, already on it
 
So i got itchy and decided i wasnt going to wait for the new gearbox.
Inspected everything and to my newbie eyes everything looks good once i replaced the worn bits with spares from rmotion.
So the "Gfab" box got put back into the car, must have been the easiest box fitting ive ever had, litrally picked it up and put it on lol hopefully this is a sign!
Stuck both shafts in and the drivers shaft is in tight! I seriously doubt itll pop back out again.
Hopefully have the car close to running tomorrow as i have a dyno day to attend on the 26th.
 
Right well ive had a time of it this past week.
The Gfab gearbox didnt work out, so the new box was delivered tuesday. Needed an input shaft bearing pretty badly so speedy delivery from tegiwa got me the bearing by weds.

Box rebuilt with my diff and new bearing, fitted and test driven wednesday. Thats all good now!
Also rewired the knock monitor so i should now get "knock per cylinder". This will allow me to see which cylinder is most knock prone and then i can take steps to protect that cylinder whilst still being able to press on with the tune abit more. Basically means i can be abit more aggressive with the tune.

Ive also changed the position of the knock sensor that pairs with the monitor. I felt that i wasnt getting the ignition timing the engine could take and that i may have been picking up a false knock reading. Im really enjoying the challenge of knock detection and the whole theory behind the event etc. Learning alot as always.

so i was due on the dyno saturday for a power run.... decided to tune the car for 18-19psi. This has shown up what appears to be a flow restriction above 7500rpm, im thinking its either the downpipe(still 2.5") or the turbo is just too small(i doubt it tbf at only 19psi) at 11.4-1 AFR this puts the injectors(725cc) over 95% at 8600rpm so its moving good air now!
Timing, ive managed to put more timing into it now ive changed the sensor placement at 19psi than i did have at 15psi before so it appears i was right to suspect the sensor placement. This has woken the car up considerably so im real pleased as it was no slouch before.
So all going well, i here what i thought was abit of det at 5500 just as ive got vtec coming in. So i provoke it abit to try and repeat the knock to confirm....
I hear a loud clunk and see something fly out the back of the car, followed quickly by my crank pulley shooting off down the motorway ahead of me! £400 crank pulley (fluidampr) flying solo away from me!
Managed to limp the car home on battery power and this is what i was greeted with


Due to not having the pulley holding it in the crank timing gear is able to move about 10-15mm and its worn the belt and the cover nearly clean through! Was soo lucky not to lose the belt(and then the engine)
Obviously this means i didnt get to the dyno day but ill book something as soon as its back!
Sorry for the long write up but had alot to say lol
 
Loving the knock per cylinder :cool:
Fingers crossed you can find the damper and it's ok.
 
Wow ! I dear say you nearly had a brown pants moment,
After that .
Really happy that you caught that belt in time.
Mark that one up as a save ! not a loss .
 
That's lucky that the belt didn't come off!

Do you have any idea why the crank pulley came off?
 
Yeah super lucky that it didnt hit another car or even worse let go on the dyno whilst i was standing infront of it!
 
SPek9 said:
That's lucky that the belt didn't come off!

Do you have any idea why the crank pulley came off?
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Could only be i didnt torque it enough i guess? I struggle to lock the crankshaft to torque the bolt up. Ill put loctite on the new bolt.
 
jesse888 said:
Could only be i didnt torque it enough i guess? I struggle to lock the crankshaft to torque the bolt up. Ill put loctite on the new bolt.
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Get a mate to sit in the car, with it in gear and brakes on.:nice:
A very lucky moment!! You could write a book with the amount of bad luck you've had with the car!
 
Murray said:
Get a mate to sit in the car, with it in gear and brakes on.:nice:
A very lucky moment!! You could write a book with the amount of bad luck you've had with the car!
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You make your own luck i guess?
I am surprised it lasted this long before it came loose aswell.
 
May have had a lucky escape this morning(time will tell), ive been running a vast majority of water in the civics cooling system.
Been meaning to sort it out but waiting on delivery, so to be safe i thought id drain the block until it turns up.

Filler caps frozen.(properly frozen). got that off and run under a hot tap.
Expansion chamber has a wall of soft(ish) ice all the way round it.
The coolant in the pipes is the same with a small passage of coolant thats still fluid in the middle. (Easily squishable by hand).
Had a look inside the coolant port for the block and thats much the same story, soft ice around the walls and coolant in the middle.
So i warmed the block with a blowtorch for a good 15mins to be sure the ice inside melted before i tried to start it. (Worried about water pump being frozen)
Thankfully it starts and seems to run fine, plenty of condensation out the exhaust as youd expect i guess but no odd noises and as far as i can tell the coolant and oil dont appear to be mixing.
Let it warm up to clear any ice but i had to be cautious because of the cambelt. Thermostat had just opened by the time i shut it off so should be all good i hope!
Worst case ive cracked a sleeve with the pressure of the ice but the radiator and everything else seems to be fine(id expect to crack a cheap ally radiator before the block/sleeves).
I didnt run it with the cap on to build pressure but the radiator wasnt frozen as squeezing the bottom hose made the coolant move at the filler cap(top hose). wondering how much colder it was last night compared to this morning?

As far as i can see another very lucky escape there! If it is ok it must have only been afew degrees from becoming totally frozen!
Must be more mindful of things like this in the future!
 
So stripped the timing belt off the car today in preporation for the new parts to go on.
Turns out the entire cambelt was being held on by only the timing belt covers
 
Surprisingly the belt looks fine, im changing it anyway but except a tiny amount of wear on the leading edge it looks perfect!
 
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