lookforjoe
True Classic
Aug 2019- I'm starting a new thread, now that I've moved from preparing for the conversion to actually performing it - only took almost a year to get to this point
12/'22 NOTE: Most if not all IACV & TPS issues (2020) were due to my initially using non-OEM aftermarket components, and with the TPS, the incorrect one for the RSX application. Beyond that, the WOT values issue was due to the shortened pedal lever, which resulted in insufficient throw at the throttle body. This is using a K-Tuned 72mm TB. Using the factory RSX TB may vary the results. 2022 TB issues were a result of my modification to the TB for cruise control installation
Mileage when speedo replaced with GPS Marshal: 139683
Preparing thread is HERE. 1st post has links and detailed info on parts / mods for the conversion.
Electrical terminal ID
INDEX:
Page 1: Aug; prelim frame cuts, MWB subframe welding, trunk floor removal, initial drivetrain test fit, shifter install
Page 2: prelim fuel sys layout, clutch hard line, rear brake layout, gas tank seal, Fuel sender/filter/float, header cuts, prelim clutch master, drivetrain removal, begin welding crossmember inserts
Page 3: Sept'19; aperture templates, SS frame inserts & aperature construction & welding/bonding
Page 4: aperture construction, right inner frame repair, bulkhead modding, priming & painting bay
Page 5: Sept/Oct; trunk access lip, left frame rail modding, rear crossmember bracing, eBrake cover modding, rear sway bar brackets, mounts, AC accumulator install, paint of rest of frame/bay area, main power cable to trunk, aperature & trunk access covers, left forward mount bracket, rivnuts for access panels, gas tank install, EVAP nitrile line install, heater valve, feed & return hose layout, brake hard line fabrication, pump, filter, FPR & fuel line layout
Page 6: Bulkhead insulation, tunnel wire harness grommet holes, AC #8 hardline to press. sw., Tunnel wiring routing, some bay wiring, hybrid axle assembly (fitment issues, operator assembly error), EMS & fuel pump wiring to trunk, rear access panel connectors, ebrake cables & rod install, undercoat, 2nd drivtrain test fit, hose, wiring, vacuum, AC frost valve, spare well relay box (bay fan wiring) & vacuum cannister bracket, prelim axle install, locked diff issue
Page 7: Nov'19; Header pie cut welds, AC low press switch housing, Clutch Master final set up, sway bar end link C/arm mounts, AC compressor hose prelim layout , Drivtrain removal #2
Page 8: Rear Hub Bearing Replacement, Cabin -Engine harness connectors, Transaxle disassembly, Bayfan sender install, Speed sensor problem, RDX injector adaptors, Fuel pressure sender & guage T, Oil temp gauge harness, AC hose crimping, Drivetrain reinstall #3 - positioning , trans fill, suspension, brakes , slave cyl fitment, Header collector align, AC compressor hose & fittings, Gas pedal mod, throttle cable & linkage setup, Battery cable install, Oil temp sender / drain plug, orifice tube layout, gutted expnsn valve install
Page 9: Nov/Dec; AC #8 condensor hose, press. sw. install, shifter cable, Charcoal canister final fit, coolant fill (and t/stat, branch hosuing leaks), Begin exhaust component layout/tack weld, replacement branch housing prelim install.
Page 10: Weld & install branch housing, begin seam welding exhaust, exhaust hanger setup, trunk & exhaust bay heat shields & floor, header shield & support bracket, design for gas pedal return spring
Page 11: Dec'19/Jan'20; Exhaust welding, modular EMS relay box mount & wiring, new tire & wheel, gas pedal return spring install, carpet install, EMS relay box wiring
Page 12: relay box wiring, spare well relay box wiring, EMS cooling fan & duct layout, EMS adaptor harness, ELD module install, mat latex backing, CIEKA test fit, EMS trunk harness, ECU & bay fan install, Spare well wiring, 1st key on trial
Page 13: Jan'20 EMS start up (wiring) issues, trunk wiring cover, Fuel sender cover, additional heat shields, software install
Page 14: Mat cleanup, clutch bleeding, 1st startup, heater core leak, final exhaust bay heat shield, TPS issues, error codes
Page 15: Heater core bypass, software teething issues, Plenum leak, custom gasket
Page 16: Feb'20; tuning, trunk carpet, ivtec emblem, 50º cam gear install, speedo gps transmitter, aux gauge panel
Page 17: aux gauge wiring/install, shifter mod, dual master setup, Cluster design, Brake Master / Clutch Master revision, drive & leak, cluster fabrication & install, CEIKA brake install, Pedal assy. Install, shifter gate assy reseal, new wheel/tire install, amp.temp gauge install, additional exhaust hanger, revise OP sender
Page 18: Feb/Mar '20; Exhaust coupler reweld, brake balance bar adjuster install, bluetooth stereo in glovebox, car washed, interior done, rework, AC compressor lines, retorque outer CV's, minor oil leaks, LS 4.9 AEM WBO2 (30-4110) , IACV issues,
Switch to RSX ECU 37820-PND-A63
Page 19: VTC housing seal, temp IACV bypass, AC compressor line fitting revision, coolant smell, RDX injector harness sockets & terminals, fill AC, 222 miles on motor
Page 20: Revise keyless entry, BT, rewire for '80 style console switches, revison of AC compressor hose layout, recrimp some AC hoses, refill AC
Page 21: IACV diagnosis
Page 22: IACV/TPS cont'd., AC low press revision, AC on circuit revision (idle comp), TPS/IACV wiring, OEM IACV install (resolved most idle issues), splash shield install, heater return hose seepage ..
Page 23: Mar/Apr' 20; SCS signal to OBDII, repl. left axle seal, rpl. #8 AC hardline with reduced barrier hose, 355 miles, revise ECU fan controller, resolve drivability / tip in issueFINALLY May 2020 Page 30 Dallara Thread Engine Cover Mesh
May 02 2020 Went off-road - damage repair thread
Page 24: 72mm K-Tuned TB and revised TPS install.
Page 25: Sept; Leakdown test - HG leak into coolant system. Castor rod bushings, revised sway bar end link. K20Z3 Cylinder Head.
Page 26: Oct/Nov '20; Layout for shifter revision (dogleg, Volvo shift & 6speed knob). Begin drivetrain removal #4. Add watercooled TIG torch.
Page 27: Nov; Drivetrain removed - NOTE: used engine support instead of hoist. Finish welds on K subframe. Water pipe removal & tunnel cover revision.
Plane block surface, assemble motor. Install MFactory 4.00:1 ring & pinion. Install SS water pipes. Install drivetrain #4, axles, suspension.
Page 28; Nov/Dec'20; Install EMS, shifter, console, mod 160ºF T/stat to fit (resolved high operating temp issue). revised ECU fan
Page 29: Console Wiring, Limiter straps for rear axles, intake cover, splash shield, dash removal
Page 30: Relay / Fuse panel (layout) removal / rewiring, Binnacle Mod Dash Recover
Page 31: Jan'21: VW wiper delay relay, (Relay Mod thread) power supply rewire, Heater box removal & disassembly
Page 32: Heater box control valve, driver side floor pan
Page 33: Jan/Feb'21: Driver's floor pan replacement section
Page 34: Radiator install mod / tub cleanup, fan wiring, wiper relay cleanup
Page 35: Feb/Mar: Frunk Fuse/relay panel, Fan connectors, VW temp sensor connector, brake ducts, heater core detail, rad hose mod, inner strut tower rust repair
Page 36: Mar '21 inner strut tower repair cont'd, trunk relay panel bracket, strut tower reinforcement, lights chime relay
Page 37: DS cowl repair, Dash reinstall, Henk Carpet prep, front speaker install, cluster re-wire/install,
Page 38: April/May'21: remove dead pedal (LS carpet install) , final rust hole - RS inner sill, RS carpet install, Engine Cover reinstall, cover strut install, 12" FFD fans install, Carlisle Import Show
Page 39: Volvo 240 HL switch, move bay fan sensor, Dyno Tune 6/01: 195WHP/165WTQ, (lack of) Cam advance issues
Page 40: June '21 cooling concerns, fan onset temp - rewire low temp to additional relay, AC compressor mount (again), exhaust restriction?
Page 41: System WBO2 issues. New Denso 234-9066 Rework O2 sensor placement downstream, Davies EWP80 consideration
Page 42: AC comp hose, TPS rewire, air ducts to oil pan, bypass breather / PCV (oil comsumption)
Page 43: Aug '21 Revised fuel filter mount, Nyack car show, comp & leakdown tests , Dyno, MWB open house trip 4047 miles on K24
Page 44: A/C compressor hose revision (again), new injectors, Dallara Wing/Trunk lid fitting, Header discussion
Page 45: Header - cut bulkhead, mod PLM header (2" runners)
Page 46: Oct '21 Header 4-2 & 2-1 collectors, exhaust layout (2.5" v-bands & pipe), lower crossmember relieving for Header clearance, top cross plate
Page 47: Cross braces, upper cross plate, trunk access panel, Hood Pin ideas. Exhaust U bend, flex, cat layout, figuring out hangers. wrong Solo Performance muffler (MACH23) Heat Shield Discussion
Page 48: Nov '21 - spot welder for access panel, muffler, tail section/resonator, left hanger install.
Page 49: Trunk floor revisions, cross brace aperture welding, engine cover latch
Page 50: latch revision, heat shielding for header proximity, exhaust install, O2 sensor failure & AFR issue, install modded cross brace
Page 51: welded DS sill/bulkhead repair, ideas for bracing bulkhead/sill/floor
Page 52: Dec'21 - sill reinforcement,
May2022 frame straightened, Dallara Wing painted, new mesh ordered for engine cover, July2022 - alt died, diagnose Cam codes
Page 53: July 2022 Fix battery drain via EMS relay & fan, determined that timing chain broke
Page 54: chain failure discussion, begin drivetrain removal #5, assemble crank/rods/pistons/carrier in replacement block, (listed steps for) drop drivetrain
Page 55: July/Aug'22 - Stripping old block, prepping replacement block, modding EMS harness, revise heater return & AC mount bracket, figure out cruise control elements, install RBC head, attach transaxle
Page 56: clean up Plenum/TB flanges, add vac ports, wire cabin side extra harness housings, run Vintage Air heater valve wiring, cruise control & WBO2 signal wiring, revise AC mount bracket on IM, figure out cruise actuator & module mounting, heater valve & pot mounted, +15 fuse panel in spare well added, cruise module bridge harness, misc spare well wiring cleanup
Page 57: Aug'22 - Drivetrain reinstall #5 (mileage at install 4727/ 144,410), new idler pulley & longer belt 6PK1670, cleanup PLM header flange & use MLS gasket, add copper gaskets to VBand flanges (3) that were sooting/leaking (creates discrepancy between WBO2 readings) first startup, add 2nd TB wheel for cruise control. Modify cruise actuator cable. Fit new SS engine cover mesh.
Page 58: Aug/Sept'22 - Quebec Pics, Cruise cable/bracket/wheel, engine cover SS mesh, AC comp rewire, Cruise pedal switches & control head installed, TB/idle control issues
Page 59: plane intake plenum, header/collector. More TB (KTuned) issues, exhaust rattle. Setting WOT values in software
Page 60 Sep'22 Throttle control, throttle pedal replacement. Walkaround video.
Page 61 Jun'23 Replaced WBO2 w Denso 234-9066. AC belt shredded. Nov'23 - real WBO2 w/ Honda 36531-RBB-003
Page 62 Nov '23 - remove ELD. Tried to buy an 80gal compressor. Added YT slideshows
Page 63 Mar'24 - replace AC clutch. New belt length 6PK1650. Note - to bypass AC use 6PK1345
* . * . * . * . * . *
So (Aug 2019), the bay is basically stripped and washed (except clutch & brake lines, not prepared to disconnect those yet)
I verified my hoist setup works nicely, lifted the rear higher to make it easier to get into the bay
Cut the first section along the crossmember first. The pas side end of the cut needs a repair section where the original was rusted through.
Removing the pas side eng mount bracket led to this (note I also removed most of the rain pocket where the ign ECU lived at one time, I plan on mounting an AC accumulator there) :
I have to make a repair panel for this area
AFM and expansion tank brackets removed
Basic tools I used: Angle Grinder/Cutter, Sawsall, Spot weld drill, Hammer & Cold Chisel. Eye, Ear & Nose protection.Tried to vacuum debris as I went, to mimize amount of sitting loose metal particles. I taped/masked off the external 1/4 & rear tail section to protect the paint (not shown).
12/'22 NOTE: Most if not all IACV & TPS issues (2020) were due to my initially using non-OEM aftermarket components, and with the TPS, the incorrect one for the RSX application. Beyond that, the WOT values issue was due to the shortened pedal lever, which resulted in insufficient throw at the throttle body. This is using a K-Tuned 72mm TB. Using the factory RSX TB may vary the results. 2022 TB issues were a result of my modification to the TB for cruise control installation
Mileage when speedo replaced with GPS Marshal: 139683
Preparing thread is HERE. 1st post has links and detailed info on parts / mods for the conversion.
Electrical terminal ID
INDEX:
Page 1: Aug; prelim frame cuts, MWB subframe welding, trunk floor removal, initial drivetrain test fit, shifter install
Page 2: prelim fuel sys layout, clutch hard line, rear brake layout, gas tank seal, Fuel sender/filter/float, header cuts, prelim clutch master, drivetrain removal, begin welding crossmember inserts
Page 3: Sept'19; aperture templates, SS frame inserts & aperature construction & welding/bonding
Page 4: aperture construction, right inner frame repair, bulkhead modding, priming & painting bay
Page 5: Sept/Oct; trunk access lip, left frame rail modding, rear crossmember bracing, eBrake cover modding, rear sway bar brackets, mounts, AC accumulator install, paint of rest of frame/bay area, main power cable to trunk, aperature & trunk access covers, left forward mount bracket, rivnuts for access panels, gas tank install, EVAP nitrile line install, heater valve, feed & return hose layout, brake hard line fabrication, pump, filter, FPR & fuel line layout
Page 6: Bulkhead insulation, tunnel wire harness grommet holes, AC #8 hardline to press. sw., Tunnel wiring routing, some bay wiring, hybrid axle assembly (fitment issues, operator assembly error), EMS & fuel pump wiring to trunk, rear access panel connectors, ebrake cables & rod install, undercoat, 2nd drivtrain test fit, hose, wiring, vacuum, AC frost valve, spare well relay box (bay fan wiring) & vacuum cannister bracket, prelim axle install, locked diff issue
Page 7: Nov'19; Header pie cut welds, AC low press switch housing, Clutch Master final set up, sway bar end link C/arm mounts, AC compressor hose prelim layout , Drivtrain removal #2
Page 8: Rear Hub Bearing Replacement, Cabin -Engine harness connectors, Transaxle disassembly, Bayfan sender install, Speed sensor problem, RDX injector adaptors, Fuel pressure sender & guage T, Oil temp gauge harness, AC hose crimping, Drivetrain reinstall #3 - positioning , trans fill, suspension, brakes , slave cyl fitment, Header collector align, AC compressor hose & fittings, Gas pedal mod, throttle cable & linkage setup, Battery cable install, Oil temp sender / drain plug, orifice tube layout, gutted expnsn valve install
Page 9: Nov/Dec; AC #8 condensor hose, press. sw. install, shifter cable, Charcoal canister final fit, coolant fill (and t/stat, branch hosuing leaks), Begin exhaust component layout/tack weld, replacement branch housing prelim install.
Page 10: Weld & install branch housing, begin seam welding exhaust, exhaust hanger setup, trunk & exhaust bay heat shields & floor, header shield & support bracket, design for gas pedal return spring
Page 11: Dec'19/Jan'20; Exhaust welding, modular EMS relay box mount & wiring, new tire & wheel, gas pedal return spring install, carpet install, EMS relay box wiring
Page 12: relay box wiring, spare well relay box wiring, EMS cooling fan & duct layout, EMS adaptor harness, ELD module install, mat latex backing, CIEKA test fit, EMS trunk harness, ECU & bay fan install, Spare well wiring, 1st key on trial
Page 13: Jan'20 EMS start up (wiring) issues, trunk wiring cover, Fuel sender cover, additional heat shields, software install
Page 14: Mat cleanup, clutch bleeding, 1st startup, heater core leak, final exhaust bay heat shield, TPS issues, error codes
Page 15: Heater core bypass, software teething issues, Plenum leak, custom gasket
Page 16: Feb'20; tuning, trunk carpet, ivtec emblem, 50º cam gear install, speedo gps transmitter, aux gauge panel
Page 17: aux gauge wiring/install, shifter mod, dual master setup, Cluster design, Brake Master / Clutch Master revision, drive & leak, cluster fabrication & install, CEIKA brake install, Pedal assy. Install, shifter gate assy reseal, new wheel/tire install, amp.temp gauge install, additional exhaust hanger, revise OP sender
Page 18: Feb/Mar '20; Exhaust coupler reweld, brake balance bar adjuster install, bluetooth stereo in glovebox, car washed, interior done, rework, AC compressor lines, retorque outer CV's, minor oil leaks, LS 4.9 AEM WBO2 (30-4110) , IACV issues,
Switch to RSX ECU 37820-PND-A63
Page 19: VTC housing seal, temp IACV bypass, AC compressor line fitting revision, coolant smell, RDX injector harness sockets & terminals, fill AC, 222 miles on motor
Page 20: Revise keyless entry, BT, rewire for '80 style console switches, revison of AC compressor hose layout, recrimp some AC hoses, refill AC
Page 21: IACV diagnosis
Page 22: IACV/TPS cont'd., AC low press revision, AC on circuit revision (idle comp), TPS/IACV wiring, OEM IACV install (resolved most idle issues), splash shield install, heater return hose seepage ..
Page 23: Mar/Apr' 20; SCS signal to OBDII, repl. left axle seal, rpl. #8 AC hardline with reduced barrier hose, 355 miles, revise ECU fan controller, resolve drivability / tip in issue
May 02 2020 Went off-road - damage repair thread
Page 24: 72mm K-Tuned TB and revised TPS install.
Page 25: Sept; Leakdown test - HG leak into coolant system. Castor rod bushings, revised sway bar end link. K20Z3 Cylinder Head.
Page 26: Oct/Nov '20; Layout for shifter revision (dogleg, Volvo shift & 6speed knob). Begin drivetrain removal #4. Add watercooled TIG torch.
Page 27: Nov; Drivetrain removed - NOTE: used engine support instead of hoist. Finish welds on K subframe. Water pipe removal & tunnel cover revision.
Plane block surface, assemble motor. Install MFactory 4.00:1 ring & pinion. Install SS water pipes. Install drivetrain #4, axles, suspension.
Page 28; Nov/Dec'20; Install EMS, shifter, console, mod 160ºF T/stat to fit (resolved high operating temp issue). revised ECU fan
Page 29: Console Wiring, Limiter straps for rear axles, intake cover, splash shield, dash removal
Page 30: Relay / Fuse panel (layout) removal / rewiring, Binnacle Mod Dash Recover
Page 31: Jan'21: VW wiper delay relay, (Relay Mod thread) power supply rewire, Heater box removal & disassembly
Page 32: Heater box control valve, driver side floor pan
Page 33: Jan/Feb'21: Driver's floor pan replacement section
Page 34: Radiator install mod / tub cleanup, fan wiring, wiper relay cleanup
Page 35: Feb/Mar: Frunk Fuse/relay panel, Fan connectors, VW temp sensor connector, brake ducts, heater core detail, rad hose mod, inner strut tower rust repair
Page 36: Mar '21 inner strut tower repair cont'd, trunk relay panel bracket, strut tower reinforcement, lights chime relay
Page 37: DS cowl repair, Dash reinstall, Henk Carpet prep, front speaker install, cluster re-wire/install,
Page 38: April/May'21: remove dead pedal (LS carpet install) , final rust hole - RS inner sill, RS carpet install, Engine Cover reinstall, cover strut install, 12" FFD fans install, Carlisle Import Show
Page 39: Volvo 240 HL switch, move bay fan sensor, Dyno Tune 6/01: 195WHP/165WTQ, (lack of) Cam advance issues
Page 40: June '21 cooling concerns, fan onset temp - rewire low temp to additional relay, AC compressor mount (again), exhaust restriction?
Page 41: System WBO2 issues. New Denso 234-9066 Rework O2 sensor placement downstream, Davies EWP80 consideration
Page 42: AC comp hose, TPS rewire, air ducts to oil pan, bypass breather / PCV (oil comsumption)
Page 43: Aug '21 Revised fuel filter mount, Nyack car show, comp & leakdown tests , Dyno, MWB open house trip 4047 miles on K24
Page 44: A/C compressor hose revision (again), new injectors, Dallara Wing/Trunk lid fitting, Header discussion
Page 45: Header - cut bulkhead, mod PLM header (2" runners)
Page 46: Oct '21 Header 4-2 & 2-1 collectors, exhaust layout (2.5" v-bands & pipe), lower crossmember relieving for Header clearance, top cross plate
Page 47: Cross braces, upper cross plate, trunk access panel, Hood Pin ideas. Exhaust U bend, flex, cat layout, figuring out hangers. wrong Solo Performance muffler (MACH23) Heat Shield Discussion
Page 48: Nov '21 - spot welder for access panel, muffler, tail section/resonator, left hanger install.
Page 49: Trunk floor revisions, cross brace aperture welding, engine cover latch
Page 50: latch revision, heat shielding for header proximity, exhaust install, O2 sensor failure & AFR issue, install modded cross brace
Page 51: welded DS sill/bulkhead repair, ideas for bracing bulkhead/sill/floor
Page 52: Dec'21 - sill reinforcement,
May2022 frame straightened, Dallara Wing painted, new mesh ordered for engine cover, July2022 - alt died, diagnose Cam codes
Page 53: July 2022 Fix battery drain via EMS relay & fan, determined that timing chain broke
Page 54: chain failure discussion, begin drivetrain removal #5, assemble crank/rods/pistons/carrier in replacement block, (listed steps for) drop drivetrain
Page 55: July/Aug'22 - Stripping old block, prepping replacement block, modding EMS harness, revise heater return & AC mount bracket, figure out cruise control elements, install RBC head, attach transaxle
Page 56: clean up Plenum/TB flanges, add vac ports, wire cabin side extra harness housings, run Vintage Air heater valve wiring, cruise control & WBO2 signal wiring, revise AC mount bracket on IM, figure out cruise actuator & module mounting, heater valve & pot mounted, +15 fuse panel in spare well added, cruise module bridge harness, misc spare well wiring cleanup
Page 57: Aug'22 - Drivetrain reinstall #5 (mileage at install 4727/ 144,410), new idler pulley & longer belt 6PK1670, cleanup PLM header flange & use MLS gasket, add copper gaskets to VBand flanges (3) that were sooting/leaking (creates discrepancy between WBO2 readings) first startup, add 2nd TB wheel for cruise control. Modify cruise actuator cable. Fit new SS engine cover mesh.
Page 58: Aug/Sept'22 - Quebec Pics, Cruise cable/bracket/wheel, engine cover SS mesh, AC comp rewire, Cruise pedal switches & control head installed, TB/idle control issues
Page 59: plane intake plenum, header/collector. More TB (KTuned) issues, exhaust rattle. Setting WOT values in software
Page 60 Sep'22 Throttle control, throttle pedal replacement. Walkaround video.
Page 61 Jun'23 Replaced WBO2 w Denso 234-9066. AC belt shredded. Nov'23 - real WBO2 w/ Honda 36531-RBB-003
Page 62 Nov '23 - remove ELD. Tried to buy an 80gal compressor. Added YT slideshows
Page 63 Mar'24 - replace AC clutch. New belt length 6PK1650. Note - to bypass AC use 6PK1345
* . * . * . * . * . *
So (Aug 2019), the bay is basically stripped and washed (except clutch & brake lines, not prepared to disconnect those yet)
I verified my hoist setup works nicely, lifted the rear higher to make it easier to get into the bay
Cut the first section along the crossmember first. The pas side end of the cut needs a repair section where the original was rusted through.
Removing the pas side eng mount bracket led to this (note I also removed most of the rain pocket where the ign ECU lived at one time, I plan on mounting an AC accumulator there) :
I have to make a repair panel for this area
AFM and expansion tank brackets removed
Basic tools I used: Angle Grinder/Cutter, Sawsall, Spot weld drill, Hammer & Cold Chisel. Eye, Ear & Nose protection.Tried to vacuum debris as I went, to mimize amount of sitting loose metal particles. I taped/masked off the external 1/4 & rear tail section to protect the paint (not shown).
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