well its another mike project that went awry and ended up being a real DUH thing in the end... so here goes:
friday night we took everything off and thought long and hard about where to go and how to do this. first thing first, move the water tank. heres where it gets kinda weird, take a look at the design of the tank in te stock location, it has that notch on the driverside, I thought to move it to where the WRXs have their tank, and it fits around that ABS hard line like it was made to do that in the first place. so i made a bracket to hold it up and ran all the hoses clockwise around the engine (avoiding the turbo) and hooked it all up. job one averted.
saturday morning now and fitting the intercooler means having to move the ignitor, TPS, and other wires along with the EGR and emissions stalk. after long and hard thought we hacked off that weird thing and clamped a hose on it to be "t"d off later. that got it out of the way of the intercooler to turbo hose. made a joiner hose and hooked that up... first fitment, the manifold to brake booster hose hit the underside of the intercooler, so we reversed it and PERFECT fit. made some brackets and ran some hoses got it all together. went over everything and rechecked what i rechecked. started it up and POOF runs great, idled a bit high, but thats all, thought it was relearning. eh, whatever, took it for a run up the hill, boost up good, BOV made a weird noise (hose a tiny bit kinked, but still worked) then bump, chug chug, thumpOOO NOOOOOOO... grrrr
limped home and checked the codes, 11 and 45, crank angle sensor and MAP sensor respectivaly enough. well, out came the lectromotive spray and air hose to clean the connectors. cleaned and tried again, STILL there, and NOOOO BRAKE BOOSTER.. GRRRRone problem averted, the brake booster HOSE has a check valve in it so do reverse it... i put some home waterheater hose insulator around it to keep the intercooler fins happy, and i got my brakes back!!! woohoo!!! still those damn codes... clean clean spray, battery terms disconnected, still there, CLEAN CLEAN, SPRAY SPRAY, hmmm whats that? i see the EGR valve (that whats it called!??!) near the fuel canister pointing away from the canister (thought that was smart as the BOV points back towards the intake) so i reversed that and zip ties the lines to that "t" to keep em on there and POOF codes gone.
so what did i learn?
1: DONT SCREW WITH THE ENGINE, LEAVE IT ALONE, but if you do, remember what you did and what points where... hehehehe
2: the brake booster hose has a check valve in it weirdly enough
3: the small EGR valve points towards the canister and a small hose popping off will give you a code 11 and 45 (no MAP goes to fuel cut which messes with the crank angle sensor)
4: can never have enough hose clamps
5: the homer beer song is good
mike
"turbos whistle while they work"
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intercooler weekend
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