This Car Hasn’t Run in 5 Years… Will It Start?

0:00 6 years ago, I set out on a quest to completely rehab this Mark 4 R32.

0:06 And today, we're this close to actually getting it running.

0:10 With only a couple of weeks left to go

0:12 before this car needs to be running and driving, we have a ton to do.

0:16 I made a pre-start checklist,

0:19 all of which we need to do before we can safely start our car.

0:24 And while this list seems like only about 10 things,

0:27 there's a million little details within each one of those.

0:30 So, we got a lot to do, and the clock is really starting to tick.

0:34 If we don't get this thing running really soon, she ain't making it to Wookies.

0:39 Time for some more fun.

0:40 So, this water pump right here is

0:43 the water pump that's going to circulate coolant

0:46 through the cooler that we're going to be

0:48 installing up front and through the intake manifold.

0:51 And this guy, with this bracket here, lives kind of over here.

0:56 I probably should have done this before I did all the wiring.

0:59 And we got to take the horn off.

1:01 I I think we're going to have to reorient our horn.

1:04 Now, the only real challenge here is they

1:05 didn't include the other side of the connector.

1:07 So, I'm probably going to cut this off

1:08 and just install a factory Volkswagen connector, so we keep it OE as possible.

1:14 This lives basically right here.

1:18 And the cool thing about it being right

1:19 here is it's really close to the battery,

1:21 so we don't have to go very far for really anything.

1:24 And we have a series of grounds all right here in the frame rail.

1:27 So, this is really about as easy as it gets.

1:30 Now, the kit included bolts and washers and nuts, but I don't love that idea.

1:35 We're going to put some rivnuts in it

1:36 because it's going to make serviceability easier.

1:38 And as I said that, I'm thinking,

1:40 I hope we don't ever have to service this thing.

1:42 I got to tell you, I love rivnuts.

1:45 What a What a great thing.

1:47 I'm hoping that soon Milwaukee Tools will get

1:49 a battery-powered rivnut tool that also is a 90.

1:54 We'll take our bracket, set that bad boy on there.

1:59 I'm going to get a bigger washer for that.

2:02 I got a bigger washer and a shorter bolt.

2:10 We'll come back and I'll cut this off and we'll wire it

2:13 with a different connector that I have a male and a female side to.

2:16 And not a necessary step, but we like to keep it VW around here if possible.

2:21 And then for our horn, of course you got to be careful doing this.

2:25 I did this on the yellow car and the horn is

2:28 aimed kind of right at the bumper and it sounds absolutely terrible.

2:32 See this 14 pin, this guy here?

2:34 I'll probably tuck it sort of back up here.

2:36 That way it's completely hidden out of the way.

2:39 I don't think this is a high draw pump.

2:41 And then the trigger is just going to be ignition power, so 15 power.

2:45 And that should be pretty easy.

3:02 Since we're on the topic of wiring,

3:05 we need to get all of these injector connectors wired in.

3:08 Now initially I was thinking, you know what?

3:09 Maybe we'll solder these in and then I deliberated and I didn't want to do that.

3:13 So we're going to crimp her in just like

3:15 we are doing a factory repair for the injectors.

3:18 And this is pretty common on most of the VW Audi cars,

3:22 Porsche cars in the last forever.

3:23 They share a power and then ground is controlled by the ECM.

3:28 So we have two wires, one power, one ground.

3:30 The bigger wire is power.

3:31 We have six of these wires that we need to wire

3:33 in and we're going to try to make it look nice, too.

3:35 There is one little section of this harness

3:37 that I couldn't get the wires stripped out of.

3:39 So in order to make sure we don't get a bunch of yuck,

3:43 a little bit of super glue does a really good job.

3:46 Clear nail polish is another thing that does a really good job of that.

3:49 We have our harness, it looks super ugly right now.

3:52 We're going to put it in the tray.

3:53 Look at all this.

3:54 All this fun.

3:56 And I'm going to hand it to you guys so you can install it for me.

3:59 Here you go.

4:00 This is very likely not the final assembly.

4:03 We kind of have to walk all this stuff in together.

4:06 If we just did one harness finished,

4:08 we're probably going to run into a situation where

4:10 where we actually need to take that harness back off,

4:12 re-route, rearrange, and then put it on again.

4:15 So, we're going to put these bolts back

4:17 in so they don't go rogue like Sara Palin.

4:20 Also, don't worry about this valve cover.

4:22 We got the solution coming.

4:25 That, I think, is a victory.

4:27 We're going to keep riding.

4:29 Now, I already sorted through some of the base wiring under the hood.

4:32 Our next step is going to be getting everything sorted with the turbo

4:36 because it kind of lives at the bottom of the stack.

4:38 First thing we're going to do for our turbo

4:39 charger is roughly set up our wastegate actuator.

4:43 I'm going to get it close,

4:45 then we got to take it back off cuz we have a turbo blanket to put on, we

4:47 have an oil feed line to put on, but I just want to get this close, right?

4:52 This actually is what controls the opening and closing of the wastegate,

4:56 which is what allows us to have boost.

4:58 So, this little arm right here swings.

5:01 Our wastegate door is open, which allows exhaust gas to bypass the turbine.

5:06 So, no boost.

5:08 When it's closed like that, that's when you have boost.

5:11 And this is the guy that does the mechanical action of it.

5:14 We talked about this a while back, but now's time to actually get it set up.

5:18 Now, I did run into an issue when we put the V-band on for the downpipe.

5:22 That little arm was actually hitting it.

5:24 Now, I probably could have clocked it different and not had that happen,

5:27 but I trimmed off the clip just a little bit,

5:31 and then I wrote myself a nice little note to make sure I checked it.

5:34 We'll do our fine adjustment once everything's on there.

5:37 I'm just going to mark this.

5:38 This is only just to make sure we get it close.

5:41 This is kind of the story, really,

5:43 for most everything we're putting on at this point, right?

5:47 Big things.

5:48 The engine's in, four bolts.

5:50 The turbo's on, four bolts.

5:53 Now it's a million fine-tuning little things that have to happen,

5:57 so it can get complicated, if you will.

5:59 So, we have our oil feed line we got to put on.

6:01 We have to get this coolant hose heightened up,

6:04 and then we can put the turbo blanket on, which

6:07 Do you want to see a really cool video?

6:09 Engineering Explained and I did a video on turbo blankets like 7 years ago.

6:14 It's when I had my turbo Mark III,

6:15 and it was like the coldest day ever in the history of North Carolina.

6:18 FLIR cameras, they loaned him like a $10,000 camera to shoot this video.

6:23 Uh so, needless to say, we were very uneasy about it,

6:26 but here's our turbo feed line for oil.

6:30 This piece right here actually goes around our timing chain tensioner.

6:34 150 years ago, when I rebuilt this engine,

6:37 we had to rebuild the stock timing chain tensioner.

6:41 This is why.

6:42 I don't know if this is the best way to provide oil to our turbocharger,

6:47 but this is how the kit is set up,

6:49 and I don't have another timing chain tensioner.

6:51 Another option would be,

6:52 especially because we have this really sweet oil filter housing,

6:55 is we could just take off and run an oil

6:58 line up and around right here to our turbo feed line.

7:01 I am going to heat wrap it, just like we did with a bunch of other parts.

7:05 Like, this is a vital line.

7:07 This line comes out, we're turbo we're destroying turbocharger fast.

7:11 This is actually from a company called Wire Care.

7:14 It's called FireFlex.

7:15 They make some insanely cool stuff.

7:17 If you're ever like, "I wonder if there's a solution for this kind of wire

7:21 covering or wiring or heat shrink or whatever," those are the guys.

7:26 And our little turbosky line here is going to be real fresh.

7:30 I mean, we're right on the exhaust manifold, so there's going to be heat.

7:33 Once I get it kind of routed where I want,

7:36 we may get a little retainer or something just to lock it down.

7:40 You're probably noticing a theme.

7:41 We're doing a lot of things that are mitigating heat.

7:44 This is our PTP turbo blanket and this just

7:49 basically goes around the exhaust side of our turbocharger.

7:52 These are usually a little finicky to get on.

7:55 Kind of in this department is sort of where we are.

7:58 So, this came with the kit, but usually when you buy these you can

8:01 get little spring hooks that hold this together

8:05 or you can just use the wire that they give you to hold it together.

8:09 It doesn't need to be like skin tight or anything

8:11 like that, but basically that's what we're looking at.

8:17 Do I seriously have no cutters in there?

8:20 What the With a blanket on, we can actually install our wastegate actuator.

8:25 I put the little nipple on and then there's a plug.

8:28 Depending on how your controlling boost in your car is

8:31 going to really depend on how this gets set up.

8:33 For us, we have an electric boost controller.

8:36 All of it's from Turbo Smart and there'll be a little

8:38 boost controller that probably goes on one of these studs right here.

8:41 For now, this is purely the mechanical connection.

8:45 Trying so hard not to drop these nuts.

8:48 That one fell on the floor at least.

8:50 I see it.

8:51 It is in the crack.

8:56 All right, round three.

8:58 There we go.

8:59 I got it.

9:00 What's next?

9:01 I wonder if we can get to that arm with the heat shield on.

9:05 So, let's do a quick test of our heat shield.

9:08 This piece our throttle body actually mounts to, so our throttle body

9:12 will sit right here and then our oxygen sensors here and here.

9:20 Did that hit the ground?

9:21 Dropping everything today.

9:24 And we have this dummy plate and I'm

9:26 betting this will give us access to our wastegate.

9:29 So, we can access both the V-band, the oxygen sensor and our wastegate actuator.

9:35 So, let's back up for a second.

9:36 Through this whole build,

9:37 I've been using the term we have to walk things in together so

9:40 that we didn't do a bunch of stuff and then go, "Oh, crap.

9:43 This actually needs to go on first."

9:46 and then back everything that we just installed out.

9:48 We can still do our oxygen sensors, we can still adjust our wastegate actuator,

9:53 but with this shield on, I need to make sure everything fits cuz if

9:56 something's cinched up in this heat shield when we go to bolt it down,

9:59 we may not realize it and what we don't want to create

10:02 the oil feed line coming out and it's like rubbing on that shield.

10:07 So, that's why it's not like,

10:08 "Do all the wiring and then go back and do something else." or do the oil thing.

10:12 I mean, we just saw in real time I had to loosen the oil

10:16 feed line because when I went to put the heat shield on, it didn't fit.

10:19 So, this is the stage where you're seeing the highlights,

10:24 but just know there's a million little ons

10:26 and offs that I'm probably having to do.

10:28 And so, you might see like I'm really optimistic and excited and then I'm going

10:33 to get really grumpy and crabby and then hopefully when we go hit the key,

10:36 it's like, "Yay!" Or it's to the floor cuz we window the block or something.

10:43 I don't know.

10:44 I got to find that bolt I dropped, which I did just now find.

10:48 I got the oil line I think where we want it though.

10:52 Our next bit of wiring is managing this long harness

10:57 and this long harness together and making it not look absolutely terrible.

11:02 So, this is the loom for our oxygen sensors.

11:05 The six wires are the upstream,

11:08 the four-wire ones are the ones behind the catalytic converter.

11:11 And normally, this all tucks and goes to a box

11:14 that holds all the connectors underneath the car,

11:17 right by the catalytic converter.

11:19 But, we've taken our oxygen sensors out

11:22 of the downpipe and putting have put I don't know,

11:24 3 in away from the cylinder head.

11:27 So, we have some work to do managing these wires.

11:30 Also, I'm a little concerned about how close these O2 sensors are to the head.

11:34 This is a high heat high high high heat area.

11:37 So, a bridged across for another day,

11:39 but first of all, the majority of this convoluted tubing,

11:45 like this is in great condition compared to how the rest of it was.

11:49 It just crumbled away.

11:50 So, we're going to get rid of all that.

11:52 We'll get rid of this T connection,

11:54 but we'll save this cuz this is actually a nice little piece to have.

11:57 And I think we can just fully separate these two pieces.

12:01 So, G39 is an upstream O2.

12:05 I don't know which one, but we know it is cuz it's six wires.

12:07 The four wires controlling it all go to ECM.

12:10 Then we have these two,

12:11 which this one is very likely going to be a ground, and this is power.

12:16 Those are our heaters.

12:17 And it looks like we share power with downstream O2, the other upstream O2.

12:24 So, here's why that's important.

12:25 Somewhere in that harness, it may be really close to the ECM,

12:29 it may be in the part we're going to look at in a second,

12:32 there is a splice that we cannot cut.

12:35 Might mess with the airflow meter,

12:36 and Volkswagen has enough airflow meter problems.

12:39 Speaking of airflow meters, don't worry about that.

12:43 Uh this Just wipe her arm is fine.

12:45 This is the airflow meter that is stock on the car.

12:48 We actually have a different one that's going to go

12:49 in um because believe it or not, this is wild to me.

12:54 This setup retains the factory air box.

12:57 Which now thinking about it means I need to get an air filter.

13:00 Chalk it up to another thing to get.

13:02 I've already labeled the two harnesses.

13:04 So, here we go.

13:06 This is the car harness and the oxygen sensor harness.

13:09 So, if you want to check the exhaust oxygen of the car in front of you,

13:15 you have enough harness.

13:16 What probably would have been a good idea on our end is

13:20 to try and find the correct oxygen sensor with a shorter harness.

13:25 The downstreams are easy.

13:27 We're going to re-wrap those and we're going

13:29 to send those back to where they came from.

13:30 So, this group, no problemo.

13:32 These, what I'm probably going to do is we'll probably

13:35 split this open and I'll pull some of this wiring back.

13:39 We can go ahead and handle this.

13:40 This is easy.

13:41 We could kind of do this into here, up and under the cowl.

13:47 I don't hate that.

13:48 I don't love it.

13:49 It's surely not going to make serviceability very good,

13:52 but we could just run all these back to where

13:55 they were and then I can take these oxygen sensors.

13:58 Like there's plenty of room.

14:00 I can basically run them down there with this harness.

14:02 Then we don't have to cut and splice anything.

14:05 I'm going to just loose tape these and then we're

14:07 going to find some kind of loom that both looks

14:11 nice and has a bit of heat treatment cuz we're

14:13 going to drop it down back to its factory spot.

14:15 And I think I'm going to do this as two separate harnesses.

14:18 The one that's the factory harness and then the one that is the other

14:22 O2s cuz we can't put the O2s on until our heat shield is on.

14:26 Look, also, let me be clear.

14:28 This is such a minor thing that I

14:30 probably should spend exactly zero seconds worrying about it,

14:33 but worst case, I'll split this loom.

14:36 I only put five or so pieces of tape on it.

14:38 We'll drop our downstreams down.

14:40 After using some brain power,

14:41 I decided to extend one of the connectors on the oxygen sensor.

14:45 That way we can plug everything in in its factory location.

14:48 Even though the shifter is not a vital part to start the car,

14:52 what I'm worried about is we're going to start

14:53 stacking things up everywhere and I'm worried this is

14:57 going to get buried up and then it's going

14:58 to be a whole big deal putting our shifter in.

15:01 So, I'm going back with the factory shifter with a couple

15:03 of small tweaks that we'll talk about while I'm installing it.

15:07 Now, in the car, I've already rebuilt that shifter box,

15:10 all Delrin bushings from Diesel Geek.

15:12 So, that's all handled.

15:14 We got to get this one in, which is a pretty easy thing to do.

15:17 Whether you're installing a short shifter from our man Pauly D or other,

15:22 it's all pretty much the same.

15:24 Also, I did repaint this with like aluminum paint from Eastwood, I think.

15:29 And I would say it came out pretty good.

15:31 You might be wondering, "Hey ding-dong,

15:33 why aren't you putting a short shifter in it?" Uh great question.

15:36 Short shifters are cool, right?

15:38 They're fun.

15:39 They give you a nice notchy feel, which I think a lot of people really chase.

15:43 I don't love it.

15:44 It feels like more work.

15:46 What I would have done actually if I had one is replace

15:49 the factory weight with like that car has an EPI or EIP one.

15:55 Uh I would do that to shorten up the shifter a little bit.

15:57 But, I got to tell you, the clunkiness, the notchiness,

16:01 uh the sometimes struggling to get into fourth gear or first

16:04 gear if it's not aligned absolutely perfect, I'm not feeling it.

16:08 So, a number of years ago I redid an R32 for Wookies for a client.

16:12 And I was like, "Hey, let's rebuild your whole shifter.

16:14 We'll do the DieselGeek Delrin super slider." I drove

16:17 the car after doing that and the shifter box, amazing.

16:20 Loved, loved, loved it.

16:22 Now, the super slider piece is just a I think it's Delrin,

16:25 but don't quote me on that.

16:27 And it lives right in here.

16:28 Normally, there's another piece of plastic

16:30 that rides in here that's really, really loose.

16:32 So, you actually get a pretty good amount of floppity from the factory piece,

16:36 where with this one significantly tightens it up.

16:47 Okay, lock locked.

16:49 Uh we got to go in the car.

16:50 So, we got our transmission side locked.

16:52 We need to lock our shifter.

16:54 Really couldn't be easier.

16:55 All we got to do is take our DieselGeek pin, drop it in just like that.

16:58 Now, if you're doing this and then you complete the task, right?

17:02 Whether that's bolting down the end links,

17:04 like if we're using a holy shift, or you're doing what I'm doing,

17:06 which is the factory setup, before you start gibber-jabbering here,

17:10 take your pin out and unlock your transmission.

17:12 Otherwise, you're going to either break this or you're

17:14 going to break the pin off in the transmission.

17:16 And you don't want to do either one.

17:17 So, I say that cuz I've done it on here like an idiot,

17:21 and then I have seen tons of those little plastic tab the lock pins break.

17:26 So, just be careful.

17:28 When we get to the interior,

17:29 it's going to be pretty cool cuz I have a lot of new parts.

17:31 You can see it Look at there's a little bit of play in it,

17:33 little bit side to side, which some of that is the sleeves here,

17:36 but almost none front to back.

17:38 New bushing New bushings in the box,

17:40 uh super slider and the sleeves and the bushings for pushing down for reverse.

17:48 It's like, "Oh, you only have 1 2 3 4 5 6 like seven things to do,

17:52 but sometimes those seven things are 35 other things that are not

17:56 on the list that have to happen before those things can happen.

18:00 It's time to get our boost controller installed.

18:03 This is kind of a two-part situation.

18:04 We got the gauge in this sweet gauge pod.

18:08 I just don't want it rolling away, so I left it in the cardboard.

18:11 And we have our actual solenoid.

18:13 So, this is a four-port solenoid, which means two connections on the wastegate,

18:17 one on the turbocharger, and one in the intake boot.

18:21 When we get there, I'll show you what I'm talking about.

18:23 I just put an alligator clip on for power.

18:25 I got a grommet for ground.

18:26 Odds are the majority of this wiring is going

18:29 to have to be different than it is right now.

18:31 Our gauge is going in the car.

18:33 This plugs into the back of our gauge,

18:36 and that's not long enough to go from where I want

18:38 to mount the solenoid to in the car with extra wiring.

18:42 So, we'll do it nice, and by we, I mean I will.

18:45 Next is a cool moment.

18:46 We'll get our airflow meter right in here,

18:48 and then this kit is supposed to use the factory airbox.

18:51 What my goal right now is to do the absolute least

18:55 amount of things so that we can fire up the car.

19:00 I think our next step is going to be to do our fuel pump upgrade.

19:03 If you didn't see when we did the install of this, I messed with this for like

19:08 20 minutes just trying to get all

19:09 the connections in and tucked in the right place,

19:12 and then I got it out in like 2 minutes maybe.

19:15 We're going to swap this guy right here out.

19:18 Doing this is actually pretty straightforward.

19:22 You do have to disassemble the housing to separate the basket.

19:26 On that note, on the one that came out of the car with all the broken lines,

19:29 you could replace just the lines.

19:31 Adding a bunch of power felt like getting a freshy setup was the right choice.

19:36 Couple of reasons why I'm going off

19:38 the reservation from the HPA fuel pump setup.

19:40 I've said many times that HPA has turbocharged a lot more R32s than I have.

19:44 So, like we have to keep that in mind.

19:46 But, the setup that they ran seemed overly

19:50 complex and introduced a ton of different failure points.

19:53 And I'm sure like they've done the testing and they haven't

19:56 had a some debris grab a fuel line from under the car,

19:59 rip it off, and create a whole big mess.

20:01 Like again, they've tested more than I have.

20:03 However, it just seems crazy when you have a drop-in pump that you can just

20:07 plonk right in and there's tons of turbo

20:10 charged R32s running around with this exact pump.

20:12 I know some people have had mixed results with this, but if we run

20:15 into a problem where we're not getting enough fuel to our engine, my fault.

20:20 So, basically instead of drilling a hole

20:22 in this, running a fuel line down here somewhere,

20:26 then a fuel line down to that dual fuel filter setup,

20:29 a line back to the inline pump that bolted to the subframe,

20:32 then from that place to the filter,

20:35 from the filter up to the front to the collector,

20:38 from the collector to the rail,

20:40 it's going to this is going to be exactly like it is from the factory,

20:43 just with a higher flow pump.

20:46 Same thing as last time.

20:47 2 seconds to remove it.

20:50 15 minutes of struggling to get it all connected.

20:53 The only other thing we might do for this pump,

20:55 and I don't think it needs it needs it, but is to add a relay.

20:59 We'll use this as signal wire and then we'll

21:01 do a separate ground and run a relay to it.

21:04 That's not going going a hold up to start the car.

21:06 Okay, big get off me.

21:09 Big moments our engine harness.

21:12 Now, I already did the injector connectors which you saw.

21:17 Here's the deal.

21:18 We're just going to set this in place.

21:19 All I want to do is make sure the car starts.

21:22 No heat protection, no soundproofing, no none of that.

21:26 This is purely crank crank crank car starts yay.

21:28 But what we what we do have to do to avoid a significant

21:32 oil loss is we have to tighten up all this oil stuff.

21:36 So, our I bet filter housing actually has two spots for oil pressure sensors.

21:41 This one would be good if you were adding an external oil pressure gauge.

21:45 So, rather than putting this in, which I was just

21:47 using this to plug the hole, I have a fun idea.

21:49 Even though we're just going to start it for a very brief period of time,

21:52 when we're cranking it before we actually start

21:56 it cuz I'll pull the fuel pump fuse,

21:58 I'll pull the injector fuse so the car doesn't start.

22:00 We want to get oil up to the top end.

22:01 We've already primed it.

22:02 We've already talked about pre-filling oil filters.

22:05 It seems that there's still sadness on the internet

22:07 about pre-filling an oil filter because it's not filtered.

22:11 Um I forgot that a number of years ago I bought a factory oil pressure gauge.

22:18 The bag 13 42.

22:21 This is the OEM factory oil pressure gauge.

22:24 So, we can get this thing on.

22:26 It's going to kind of be in the way cuz this is giant.

22:29 We'll be able to monitor oil pressure as we crank and start the car.

22:31 So, that's cool.

22:32 I'm going to tighten down our oil fittings.

22:34 I wonder if anybody like thinks about that movie Remember

22:37 the Titans when they think to remember to tighten something.

22:41 Anyway, yeah.

22:43 I'm not saying it's a good like reference or whatever.

22:47 Remember the Titans.

22:48 Hey, listen.

22:48 Here's my theory on it.

22:50 Whatever you got to do to remember to tighten stuff,

22:52 that's what you should be doing.

23:00 So, we got these connectors we got to connect our main power wire.

23:05 This is all that secondary air stuff.

23:07 I'm going to try, I don't know if I'm going to be able to find the right pins,

23:10 but I might try and make this an actual fuse

23:12 panel right here cuz it's got the little ports for it.

23:15 That way we can retain factory, but we're so far away from that right now,

23:18 there's no point in even worrying about it.

23:21 If any of this wiring looks familiar and you saw the Lupo series,

23:24 basically not the same harness, but similar harness.

23:28 That feels really good.

23:29 I'm going to find the bolts that hold that down

23:31 and we can just go ahead and be done with that.

23:34 So, if you didn't see the video where

23:35 we actually installed the engine in, I had what

23:38 I thought were the correct bolts for the engine

23:42 mount into the bracket that bolts to the engine.

23:44 Uh it turns out they were, I don't know,

23:47 20 mm too long and so in an effort to not let that hold us up,

23:52 I just stacked a bunch of washers on with the bolts I had.

23:55 Could I have cut them down?

23:56 Of course, I could have.

23:57 Did I want to?

23:58 No.

23:59 Those are brand new bolts that go somewhere.

24:01 We have another R32 right behind us.

24:03 At some point, I'll need those.

24:04 Uh so, I just got the right ones.

24:07 Having seen plenty of engine mount replacements,

24:10 I am not even upset about what that looks like cuz I've seen worse.

24:18 On a plus note, I get my 37 washers back.

24:21 It did the trick.

24:31 Man.

24:33 You got to love a good click.

24:38 It's time to start putting fluids in this car.

24:41 This is some pig mat that we had put down when

24:44 we did the yellow car swap and this stuff is awesome.

24:48 Trying to account for our brake fluid that definitely is going to spill.

24:51 In a perfect world, I would have got new drain plugs for this, but I didn't.

24:56 Servicing all these fluids pretty short after like the initial drive.

25:00 Like maybe it's before Wookies we can put 100 miles or so on the car,

25:04 come back in, change all the fluids, and send it.

25:07 To be honest, I'm not sure if we're going to have time for that.

25:10 Diff fluid and Haldex fluid in the back.

25:13 Filling these diffs pretty easy.

25:15 Remember, uh you just basically take the drain plug out, drain your fluid,

25:21 take the fill plug out, pump fluid in until fluid comes out.

25:25 Q that you should have taken the fill

25:27 plug out before you took the drain plug out.

25:29 We're using the regular hypoid gear oil from Liqui Moly.

25:33 Remember, we put a limited slip differential in this thing and best

25:36 I can tell we don't need any extra additives for that limited slip.

25:41 That's a gear limited slip.

25:42 It's not like the Mustang we did where it has

25:45 clutch packs in it or a springs or anything like that.

25:47 It's purely mechanical, more like a Torsen style diff.

25:51 So, we shouldn't need any special cool additives or anything like that.

26:02 Easy.

26:02 Diff done.

26:03 Next, Haldex.

26:06 See, oh, good lord.

26:09 I would have never got that loose with that little one.

26:11 I'm pretty sure we drained this because I had

26:13 the pump out and I had I think the cover off.

26:17 But I don't remember tighten the hell out of this.

26:19 Oh, I'm glad we took that drain plug out.

26:21 Fluid coming out is a little gross.

26:23 Very likely, just like I was saying with the diff, we'll drive the car,

26:27 put some mileages on it, bring it back, change the fluid out.

26:32 For Haldex fluid or multi-clutch multi-disc clutch oil,

26:37 you really have to shake these up.

26:39 These will settle and you'll get like crunchy stuff down at the bottom.

26:43 Factory fluid, any of it, it all does it.

26:46 So, really make sure you give your jugs a good shake.

26:51 Okay, so we can't fill it on the backside.

26:54 Now it's going to make a mess.

26:55 Crap.

27:10 Transmission next.

27:12 With these transmission fill and drain plugs, they require a specialty socket.

27:16 It is a tamper-proof triple square.

27:18 You fill the transmission same way you do the diff.

27:20 Drain the fluid, put the drain plug back in, fill it through the fill hole,

27:24 and then once it starts to come out, that's the basis of it.

27:28 Uh it looks okay.

27:30 Pretty clean.

27:31 Because we have the front end off,

27:34 uh I have a faster solution than the the hand pumpy pumpy.

27:38 We're going to shove the tube in.

27:40 Might even be able to use some of this wiring to hold our funnel.

27:42 Look at that.

27:43 Look at that.

27:44 Minty.

27:44 This has a funnel in it or a filter in it, too.

27:47 So maybe Listen, oil friends that don't want to pre-fill your oil filter,

27:52 maybe you just need to get a funnel like this.

27:54 It's got a little screen in it.

27:55 All your problems are solved.

28:07 Choo choo.

28:09 It's time for something big.

28:11 I choo choo choose you.

28:13 It has a picture of a train.

28:15 Okay.

28:17 Big moment.

28:18 Time for our manifold.

28:20 HPA doesn't use a gasket.

28:21 They tell you to put RTV on that.

28:23 I'll be real honest, I hate that so much.

28:25 I'm sure there's a reason, and that's fine.

28:28 We'll default to HPA for that, but the fact

28:30 that there's no intake manifold gasket, don't love it.

28:33 Same thing with the throttle body.

28:36 RTV, I guess, is the solution.

28:38 We'll probably make some gaskets.

28:39 Not a thing I'm going to I'm going to go too crazy with.

28:42 Again, they've done more testing on turbo R32s than I have,

28:44 but that one I don't I don't even want to pretend to understand.

28:48 The bolt holes here for the intake manifold are M7, which is a very odd size.

28:53 Now, in the limited instructions that we got,

28:55 it says you got to cut down the factory ones.

28:57 However, what I found is that bolts for multiple piece BBS wheels,

29:03 same size, same thread pitch, and you can get them in different lengths.

29:06 This is one of the very first beauty washer kits that I got from Zelas.

29:11 This is cool.

29:11 It's cool to finally put these on.

29:13 That this I think went like this.

29:18 Man, no gasket.

29:19 I just I was annoyed about the exhaust manifold to turbo not having a gasket.

29:25 The difference there is that we know the exhaust

29:27 manifold and turbo charger surfaces were both machine flat.

29:31 This was probably machine flat.

29:34 This was not.

29:35 Which means the likelihood of having a very

29:38 small imperfection in one of these pieces

29:40 causing an air leak either sucking on metered air in, which is not as likely,

29:45 or blowing boost out, which is more likely.

29:48 And honestly, that's probably why they don't have a gasket

29:51 is because they didn't want to create a potential boost leak.

29:54 But the turbo charger cars from the factory have a gasket.

29:58 Maybe we make like a paper gasket.

30:00 I'll do some digging,

30:01 but just not having a gasket provision, I don't understand it.

30:17 Okay.

30:26 That looks pretty dope.

30:27 I'm suddenly wondering, does the throttle body actually go like this?

30:29 I don't know that the hood's going to shut.

30:31 It It doesn't really matter for this thing that we're doing,

30:34 but um yeah, it probably doesn't go that way.

30:37 Now, I will say, if we're not able to get like face on like we are right here,

30:41 this is going to be a real pain in the butt to get these bolts off,

30:44 but if we're taking the manifold back off,

30:48 something bad has happened and the whole front

30:51 end of the car is probably coming off anyway, so I'm not too worried about that.

30:54 What I'm doing now is just looking at a handful of things

30:56 and I've just noticing like this clip for the fuel pressure

30:59 regulator probably would do better to come from the other way

31:02 cuz it's going to there's going to be a hose right here.

31:04 It's going to butt right up against that clip.

31:06 Our fitment on both sides of the fuel rail honestly super tight.

31:10 We also need to still work through what this harness is going

31:13 to look like because the bracket is not going to really work here.

31:17 Anyway, problems for other days.

31:20 This is awesome.

31:22 I'm always going to just call this unfiltered oil from now on by the way.

31:26 I'm just going through like we should have every all the oil system sealed up.

31:30 I can't picture world I'm never going to let

31:33 this go where there isn't some level of filtration that happens.

31:38 Is it better than the car's factory oil filter?

31:41 I don't know.

31:42 I got to put a boost pipe on.

31:43 I have to go get a battery cuz I don't have one.

31:45 We got to put the cluster in, plug our fuel pump in, and then it's time.

31:50 Boom.

31:51 Hold on.

31:52 Ooh, that one was really good.

31:56 Dang.

31:57 Dang.

31:59 Uh, okay.

32:00 We made a pivot on our fuel system, right?

32:01 Midway through doing the HPA setup,

32:04 which means we're going to ditch these dual Oh.

32:08 I was like, I'm going to have to really work to get these out.

32:11 I apparently never tightened the clamp, so easy.

32:14 So, we're going to hook this back up just

32:16 as it was from the factory with a new fuel filter.

32:25 Gross.

32:26 All right, those are kind of positioned where they need to go.

32:28 We'll get everything locked in.

32:29 I got to get the another clamp to clamp this down.

32:32 I just don't think I have one quite big enough,

32:34 but also what just came is our downstream O2s, which live here and here.

32:38 Just like with the fronties, one short connector and one long boy,

32:43 cuz one of them has to go up and around,

32:46 and then the other one just has to like boop around a little bit shorter path.

32:49 So, it is time for a huge moment.

32:54 So, many many years ago when I got this cluster,

32:57 I sent it to Clusters by Lit Key to have him redo it.

33:00 It's not been plugged in since I've had it.

33:02 You can see the layer of dust on it.

33:04 Look and all sad.

33:05 But, if you'll notice, he did put purple needles, which is awesome.

33:08 I just was like, "Matt, do whatever you want." And he's like, "I got you, fam.

33:12 Let's go." Very excited about this.

33:15 This has our immobilizer in it.

33:17 So, if we don't put this in now, the car won't start.

33:20 And we're just that close.

33:23 That close to starting it.

33:24 And then that close to actually driving it.

33:28 This sweet intake manifold that we just put on, uh I have to take

33:31 back off because we won't be able to get the fuel rail fitting on.

33:35 Luckily, the front of our car off though, this is not very hard.

33:40 Remember like the quote of the series is you got to walk everything in together.

33:46 I wish that was a better slogan and we could put it on a T-shirt.

33:49 Uh but, it's a terrible slogan to put on a T-shirt, I think.

33:51 I don't know, you let me know.

33:52 Is it good or bad?

33:53 Um this is perfect case in point.

33:56 This clip, even slid all the way over,

33:59 is too close to that coolant outlet on the manifold.

34:03 So, I need to take this clip off and flip it.

34:05 But, I can't do that cuz it's hitting the valve cover.

34:07 I cut the tabs off the cap.

34:09 I couldn't even get our cap on and off.

34:10 It actually has me a little worried that our fitting may

34:14 end up hitting the manifold if we don't clock it perfectly right.

34:17 So, we're waiting on a different fitting.

34:19 This is not the right fitting, but it'll look almost the same.

34:21 It'll just be barbed like the return line.

34:23 That way we can go fuel in to injectors,

34:25 and then pressure regulator will control fuel back to the tank.

34:29 Since we're not going to have power steering, air conditioning, or coolant.

34:33 I'm going to take the serpentine belt off,

34:35 and the main reason is I don't want to dry pump the power steering pump,

34:38 the AC compressor, or the coolant pump.

34:40 Just pop that guy off.

34:42 We don't even need to take it off the car.

34:43 It's a 3000GT belt cuz it's Mitsubishi.

34:46 I have another thing we have to do before starting this car,

34:49 and that's re-pin our fuel pump connector.

34:52 Four pins, super easy, barely an inconvenience.

34:56 Look at this, wrong hat.

34:58 Uh by the way though, I don't wear hats all the time,

35:01 but when I go incognitus, this is the hat I like to wear.

35:06 Yeah, if you're like,

35:07 "Who's that gangster in the Milwaukee hat?" It's probably not me, actually.

35:12 So, we either break it the rest of the way so there's no lock tab,

35:15 which for this is fine, or we re-pin it.

35:18 And I'm choosing I'm choosing re-pinning.

35:21 This fine piece of engineering that I made is the metal like strip

35:26 out of a wiper blade that I ground down to the appropriate size,

35:30 and then you can see I just barely bent the tips.

35:33 This is such a good wire pin tool.

35:35 We don't want to actually start the car on like first key cycle.

35:40 We're going to crank the car a little bit so that we

35:43 can build up oil pressure before it has any opportunity to start.

35:46 I'll also pull the fuse for the fuel

35:48 injectors and maybe one or two other little components, but we got a freshy.

36:01 Something that I probably should have already installed,

36:03 but didn't, is this after run coolant pump.

36:05 And so, what these do is these allow

36:07 coolant to circulate after you shut the car off.

36:09 I have no idea why I have this or where it came

36:12 from, but it is less grungy than the other one that I have,

36:17 so we're going to go with this.

36:20 Yeah.

36:24 There it goes.

36:26 Man, that drinks this water quick.

36:29 It's working.

36:30 We haven't talked about coolant at all yet.

36:33 These are from Autobahn Autoworks silicone hoses.

36:36 A lot of these R32 hoses you can't get anymore, right?

36:39 And so, Travis has made hoses, which is awesome.

36:43 If Autobahn Autoworks sounds familiar to you,

36:46 it's because we used his radiator when we did

36:49 the 07K swap in the Caddy pickup truck rabbit pickup truck,

36:53 and it was fantastic.

36:54 We got all new hoses for this thing.

36:56 The only thing that's not going to have

36:57 proper hosing like these nice silicone ones is going

37:00 to be our secondary cooling system that we

37:02 have for the intercooler and for the intake manifold.

37:06 I did need to use the worm clamps that came with the kit,

37:09 which kind of makes sense.

37:10 Remember, this is what came off the car,

37:12 which means this is what the majority of the spring clamps look like,

37:16 which is gross and ugly.

37:17 Got this ready to go now.

37:18 Since we still have our serp belt off,

37:20 let's see if we can shoehorn this bad boy in.

37:24 By the way, this would never be happening if

37:26 I didn't have the front of the car off.

37:29 It's the little things.

37:30 We can actually just kind of finish this job right here.

37:38 We have arrived.

37:39 I have my fuel fitting that is going to go on our rail.

37:42 Now, this I don't think it's going to be the final

37:45 solution because watch how this is going to stick up.

37:48 It's going to be weird.

37:49 But, for the sake of starting this car, it's going to be totally fine.

37:51 These are fuel lines off of this car originally.

37:54 They're going to go here and here on the factories.

37:56 We'll put the return there.

37:58 These are a little dry rotted, so we may not run these.

38:03 This probably never come off.

38:21 This thing hasn't had a battery in it.

38:22 It hasn't quite been 6 years.

38:25 I pulled the loom holder off of our coil

38:27 connectors cuz we're have to redo it anyway.

38:30 Uh I'm not sure exactly what what that's going to look like yet.

38:34 All right, let's see.

38:35 See if it'll power on our little gauge here.

38:39 Doing things, cool.

38:40 Uh fuel?

38:42 How about we put some fuel in it?

38:44 I'm excited because this is like a big step and like obviously it has to happen.

38:49 I'm trying to temper that with there is still so much work.

38:54 Like whatever work we've done to up to this point,

38:56 I don't even know if we're like halfway there yet.

38:59 We have oil in the car, we have fuel in the car.

39:02 I'm sure I'm forgetting something.

39:03 Let's put the maintainer on it.

39:05 We're going to turn the key on.

39:06 I'm going to pull the fuse for the fuel injectors.

39:08 Our pump is still disconnected.

39:09 So either way we shouldn't have this car start yet.

39:12 I want to see some movement of our oil pressure gauge.

39:17 Ooh.

39:19 Yes.

39:23 This thing is going to be It's It's so mad and I

39:31 don't even have any way like there's no buttons to turn it off.

39:34 This is not the right steering wheel.

39:35 So I apologize for the beeping.

39:39 So I have no calm with anybody right this minute.

39:42 Um I'm going to crank it and see

39:43 what happens cuz obviously our cluster is working.

39:55 She cranks.

39:56 Now what we got to see is do we actually get oil pressure on our gauge or not?

40:09 Okay, we have oil pressure.

40:11 I don't have calm yet so the car may

40:13 not start but let's get our fuel system hooked up.

40:15 See what happens.

40:16 I would say we should hear that fuel pump prime,

40:18 but with all the banging this is doing, we probably won't hear it.

40:29 I heard something happen in there.

40:31 I'm a little nervous.

40:33 I don't normally get this nervous, but it's been a long like journey,

40:37 so nothing to do but to do it.

40:43 Okay, no surprise.

40:45 Got to build up fuel pressure.

40:52 Okay, I definitely did not mean to shut that off.

40:55 Holy crap.

41:07 I'm not sure if I'm more nervous or less nervous now.

41:16 We have nothing connected, so it's not surprising that it doesn't stay running.

41:29 It smells really Uh, look at my hand's shaking.

41:35 Wow.

41:36 Okay.

41:38 Uh, here's the positives.

41:40 It started.

41:41 The negatives is why the hell don't I have communication with anything?

41:44 With no air flow meter, a giant no hose on the throttle body,

41:49 not an adaptation of the throttle body,

41:51 it's really not surprising that um it doesn't run.

41:53 I think I'm going to start it one more time and try and give it a little RPM,

41:57 like with the a gas pedal, and see.

42:00 If it revs up, I'm feeling pretty good about it.

42:03 If it doesn't and just still shuts back off,

42:06 we may have some kind of issue going on.

42:09 I I know, a immobilizer or what or just the fact that we can't talk to anybody.

42:19 Okay.

42:20 I'm happy.

42:21 I think that's worth celebrating.

42:24 But, with that, we still have so much work to do.

42:28 What I want to do now though, one, it smells really bad in here.

42:32 Two, let's make sure we didn't puke any fluids out.

42:36 I don't see a giant puddle of anything.

42:39 I think I mean, granted we don't have power steering fluid,

42:41 brake fluid, coolant, or anything, but there's no oil that puked out.

42:44 We don't have a giant Oh, we do have a fuel leak though.

42:47 Funny enough, it's not my janky fitting.

42:50 This is wild.

42:51 We got to figure out why it doesn't talk,

42:53 but we'll cross that bridge when we get there.

43:00 It started!

43:01 Yes!

43:03 I think we can collectively all celebrate this moment.

43:05 This is huge, right?

43:06 The way I'm seeing it right this minute though,

43:09 is that this kind of marks like just under the halfway point.

43:13 Still so much to sort through.

43:15 I do want to just take a minute and celebrate.

43:17 And what else I want to do, is I want to tell you guys thank you for not

43:20 abandoning this project like it probably feels like I did.

43:24 I know it's been a long journey and a long time,

43:26 but next major milestone is when we can hit the key and drive it,

43:31 go fill it with fuel, and take it for a rip.

43:34 That will be the biggest victory of all time.