Member Profile - cynner

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Re: Member Profile - cynner

Postby cynner » Fri Jul 24, 2015 9:36 pm

An unfortunate turn of events... (or fortunate, depending on which way you look at it).

Having been chasing 'phantom knock' for over 6 months, and having replaced pretty much every possible part that could cause phantom knock, I decided to replace the oil pickup (thinking perhaps the knock was caused by the stock oil pick up splitting and sucking up air, preventing good flow to the bearings).

Anyway, the oil pickup was fine - but my mechanic noticed metal chunks in the sump :(

metal-chunks.jpg
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The smaller chunks are magnetic, and the larger chunk is alloy. My mechanic was able to turn the crank and could not see anything obviously broken, however he was able to wobble #2 rod by hand (in an up/down direction)... so suspects the big end bearing for #2 cylinder has worn. Perhaps a chunk of it has got jammed somewhere and broken off a chunk of cylinder, who knows.

Anyway, to cut a long story short - I figured there was no point putting the sump back together and continuing driving like that – so the engine is out, and a refurbished 'built' engine is currently being checked over, before getting put in.

engine-out.jpg
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The new engine specs are:

MY06 WRX complete engine (EJ255). Bottom end has Manley rods, Mahle pistons, ACL race bearings, Cosworth oil pump, new oil cooler, cylinders bored out to 100mm. The heads were overhauled and the larger WRX valves compared to the Liberty, and have Cosworth valve springs and head gaskets, ARP headstuds and case bolts. The engine has around 20,000kms on it since the original build, and will have the bearings replaced and everything inspected before I take ownership of it. I'll also put in a fresh timing belt kit and water pump, plus equal length headers.

It will be quite a different beast!
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Re: Member Profile - cynner

Postby THE SpecB » Fri Jul 24, 2015 9:57 pm

Kim could be a blessing in disguise to get this done hope new engine is all good once checked out and you can enjoy the lib again :)

Can this issue be caused by tune related ?
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Re: Member Profile - cynner

Postby cynner » Fri Jul 24, 2015 10:06 pm

THE SpecB wrote:Can this issue be caused by tune related ?


Not sure... probably more likely that a tune = more power = more likely something will go wrong.

Things that happened at around the time I started noticing this issue:

- had a new turbo fitted (seemed ok for a while after that)
- had a new fuel pump fitted (seemed ok for a while after that)
- had an oil change done (and I noticed it was slightly over-full on the dip stick, so I drained 200ml)
- went on road trip that require driving about 100km on a very very bumpy road
- had also done a fair bit of logging and a dyno run
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Re: Member Profile - cynner

Postby gtbsti » Sat Jul 25, 2015 8:34 am

great to hear it's all getting sorted mate.
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Re: Member Profile - cynner

Postby AJ RS » Mon Aug 24, 2015 9:18 pm

How's progress mate? Back on the road yet?
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Re: Member Profile - cynner

Postby cynner » Mon Aug 24, 2015 9:35 pm

Going slowly... the mechanic had a couple of setbacks. One of the rings bent when the engine was being re-assembled (after new valve stem seals and ACL bearings). New Mahle rings ordered and fitted. Then when tightening the case bolts, one of them threaded the case – so they had to dowel the case and use heli coils. Bit of bad luck I guess - but at least the mechanic is covering that, just means a delay for me. This week the engine will be all assembled ready for the intake manifold to go on, with parallel rail mod, etc. And hopefully next week it'll all be back in the car!
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Re: Member Profile - cynner

Postby AJ RS » Tue Aug 25, 2015 7:12 pm

It will be worth the wait ;)
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Re: Member Profile - cynner

Postby cynner » Sat Sep 26, 2015 10:48 pm

The new engine is in, with a run-in tune.

However the bad news is... I still have the phantom knock :evil:

There's no doubt the stock engine had issues (metal chunks in the sump, and one of the rods could be wobbled about by hand) - but that wasn't causing the phantom knock.

So all that leaves is the turbo really. Or ECU.

So now I'm looking for a replacement turbo... thinking even just a VF52, but seems a shame to have a built engine with 1000cc injectors, etc... and not a big turbo. Can't really afford a gt3076...

Kim
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Re: Member Profile - cynner

Postby HardwareBoB » Sun Sep 27, 2015 9:31 am

cynner wrote:The new engine is in, with a run-in tune.

However the bad news is... I still have the phantom knock :evil:

There's no doubt the stock engine had issues (metal chunks in the sump, and one of the rods could be wobbled about by hand) - but that wasn't causing the phantom knock.

So all that leaves is the turbo really. Or ECU.

So now I'm looking for a replacement turbo... thinking even just a VF52, but seems a shame to have a built engine with 1000cc injectors, etc... and not a big turbo. Can't really afford a gt3076...

Kim

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Sure you can :)
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Re: Member Profile - cynner

Postby cynner » Sun Sep 27, 2015 10:49 am



Tempting! My mechanic is going to try to help me out with a good price on a Dom 1.5xtr. Will have to see what the price comes back as...
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Re: Member Profile - cynner

Postby peadya100 » Wed Sep 30, 2015 8:53 pm

1.5!!!
That will be a weapon if you get one of those. MSR's track car makes 360wkw with a 1.5 :good:
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Re: Member Profile - cynner

Postby THE SpecB » Wed Sep 30, 2015 9:21 pm

peadya100 wrote:1.5!!!
That will be a weapon if you get one of those. MSR's track car makes 360wkw with a 1.5 :good:


How much horse power is that ?
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Re: Member Profile - cynner

Postby cynner » Wed Sep 30, 2015 10:14 pm

Changed plans slightly on the turbos... going for an ATP STi Silver (Garret, ceramic ball bearings, billet wheel, cnc actuator). Similar to the ATP Gold, with slightly smaller housing so the mid-range will be better. Similar to a GTX3071R.
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Re: Member Profile - cynner

Postby alexeiwoody » Wed Sep 30, 2015 10:15 pm

THE SpecB wrote:
peadya100 wrote:1.5!!!
That will be a weapon if you get one of those. MSR's track car makes 360wkw with a 1.5 :good:


How much horse power is that ?


Newbie, have you tried:
http://www.convertunits.com/from/kW/to/horsepower+[international]?

Or http://www.google.com.au?

I find they're both really helpful. :)
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Re: Member Profile - cynner

Postby bigBADbenny » Wed Sep 30, 2015 11:33 pm

cynner wrote:Changed plans slightly on the turbos... going for an ATP STi Silver (Garret, ceramic ball bearings, billet wheel, cnc actuator). Similar to the ATP Gold, with slightly smaller housing so the mid-range will be better. Similar to a GTX3071R.


Garret core brings a good upgrade path eg rear housings.
So start off with the turbine that lets you start with a decent iwg rear housing but let's you upgrade later to eg a Tial SS V band rear :good:
You can do that w/ either a stock location ewg up pipe on the Killer Bee Spoolinator adapter or eg a twist mount ewg uppipe :shock:
Garret, Treadstone are other options of course...
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