500 HP minivan slayer

Discussion in 'Mazdaspeed 3 Build Diaries' started by DR. K, Nov 25, 2022.

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  1. DR. K

    DR. K Greenie Member

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    Watch out, Karen, your Sienna is about to get gapped. I found a 2008 MS3 with 100K miles and a blown head gasket for $2,400. The car has been "rode real hard and put away wet." Here is its rebirth with a chance to regain some of its dignity. A 500 HP daily is the goal.
    [​IMG]

    Build list
    (updating as I go)​

    Intake-
    Exhaust-
    Short Block-
    Timing and gaskets-
    Cylinder Head-
    Machine work-
    • Bore, deck, and clean block
    • Balance rotating assembly
    Fuel system-
    (Returnless auxiliary port injection system- 340 LPH in tank pump to HPFP to the auxiliary fuel rail)
    Drivetrain-
    Miscellaneous Electrical-
    Miscellaneous General-
    • Freektune HAVE NOT BOUGHT YET
    • Crash bar HAVE NOT BOUGHT YET/ I may build this
    • Fog light lenses HAVE NOT BOUGHT YET
    • Windshield- $200 installed HAVE NOT BOUGHT YET
    • Rear L stabilizer link HAVE NOT BOUGHT YET
    • New fender flares HAVE NOT BOUGHT YET
    • New tail and brake light lens assemblies
    • New headlight lens assemblies HAVE NOT BOUGHT YET
    • New front wheel wells (Carparts.com)
    • Paint the front right fender MAY WRAP THE ENTIRE CAR WHITE INSTEAD
    • Replace L front lug stud and get lug nut
    • Brake pads and rotors front and rear w/ hardware HAVE NOT BOUGHT YET
    • Tires 285/35R18 97H Contiprocontact radial (All Season)- HAVE NOT BOUGHT YET
    Here is a picture of the car right before I picked it up. It's lowered with BC BR coil overs and sits on 285/30/18s. It had an Accessport, aftermarket intake, smaller front mount intercooler, HPFP internals, a GFB bypass valve, aftermarket downpipe, and straight pipe out the back with no muffler. bgh.jpg

    Here is a picture of the car when it was originally built by someone who actually cared about it. 311898579_10228997642426283_2028090992448541124_n.jpg

    Here is why I say it was "rode very hard " and put away wet: It actually ran but was misfiring very, very badly when I got it. The head gasket was indeed leaking badly. Upon removing the head, I could tell it had been driven a lot with the head gasket blown. The downpipe had been broken off right before the cat and clearly driven that way for a while. It had been sitting for over a year.
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    There was significant rust in the cylinders.
    312081543_10228993194715093_8031325192784288698_n.jpg
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    The right front strut rod had a loose nut at the strut mount and had been driven in that condition for a long time. The strut rod was worn almost halfway through! It has a broken stabilizer bar link; the injectors basically had no seals on them; the K04 turbo is clapped out, the engine oil was creamy brown, and the crank bearings were badly etched, the tires have brand new tread depth, but they are from 2012 and have bad enough dry rot cracking that I can see cords. The fog light lenses are busted out, the headlights and tail lights appear to have a film of tint on them that is in terrible shape when you are up close, there is a mismatched fender, and the interior was FULL of mold from sitting with water in it at one point, the brakes are worn down, the fenders are cut and left bare metal at the cuts, the fender flares are sun rotted and brittle fiberglass, there is a crack in the windshield, and honestly I could go on!
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    I went ahead (with the help of my astute assistant) and removed the short block. It was clear that I would be lucky if I could have the cylinders bored enough to clear out the rust and still fit 88mm pistons.
    312631757_10228993197035151_1575237318420338569_n.jpg

    My assistant clearly looks concerned, as was I. The CV boots are torn, and the transmission mount is still stock.
    311947006_10228993196795145_7650408146091716926_n.jpg

    We were short on time, and someone... hadn't had their nap, so we just popped the short block out the top to save some time in the day. We also discovered a cooler line was rubbing a hole in the intercooler on the back side. One thing after another.
    312259885_10228993197275157_5122946392366364968_n.jpg

    This is a nasty little short block...
    311932521_10228997640226228_7411086814403645661_n.jpg
    312105893_10228997639306205_7053953474675541302_n.jpg

    Next came disassembly to learn if I would be able to save the crankshaft. It turns out I prevented a lot of damage just in time. Some of the rod bearings showed significant copper and had bad etching. Luckily the crank was in great shape. There was one ring land that had some damage, but it was early into the destruction. The head had a temperature tag and was clearly a reman. It was really clean inside it. Unfortunately, this thing got really, really hot, and the cam journals were no longer perfectly aligned. When I torque the cam caps with the cams in them, I can barely turn the cams. A few journals were galed and damaged the cams as well. I can post some pictures if anyone wants to see what that looked like. I called around, and no machine shops in my state so far align bore journals this small, so I'll be using a different head.
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    I'll take a break from the destruction for a few posts and focus on some of the exciting movement on Project Shit Show. I procured a brand new CST5 and a bunch of other go-fast parts in the last few weeks. This hair dryer is set up for an EWG, and I have a 44mm Turbosmart wastegate. 313865362_10229119678317104_8974212133788231400_n.jpg

    I got lucky, and my machinist was able to get the rust cleaned up in my cylinders for running the 88mm Manley pistons. When I handed him the pistons, he said, "oh, those are cute" lol.
    20221122_132520.jpg

    Chris Ward with CW Turbocharges has been phenomenal to work with and has sent me lots of parts. I highly recommend him. I'll make a post with all my parts and modifications in a nice organized list, but here are the things I have so far as I think of them. I scored and snagged a fresh set of Manley H-beam rods from someone who no longer needed them. I have Manley 88mm pistons, Supertech 70lb valve spring and retainer kit(wanting to turn 8K RPM), King rod, and main bearings sets, ACT clutch kit, Focus ST manifold, Under route intercooler piping for the ST manifold, AEM 340 LPH in-tank fuel pump, CS balance shaft delete kit(rotating assembly is being internally balanced), Grimmspeed 3-port electronic boost control solenoid, ARP L19 head studs, ARP main studs, Damond Motorsports ST manifold port injection adaptor plate, Damond Motorsports returnless fuel line kit, Injector Dynamics 1050 CC injectors, Split Second Controller,
    20221119_122226.jpg
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    I have filled several motor mounts in the past, and I think this kit is pretty neat. I went with a urethane that is rated 80A on the Shore hardness scale. I felt like it was a good balance for the power and the daily driving use. If I don't like it, I'm only out about $100. The rear engine mount is already aftermarket on this car. I'll post some pics of the process of filling the other two mounts when I do it.
    20221124_211939.jpg
     

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    Last edited: Jan 5, 2023
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  2. Easter Bunny

    Easter Bunny Professional Engineer Motorhead Platinum Member

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    Looks like quite the undertaking but your making progress

    Just so you know balancing the internals does not negate the need for the balance shaft assembly, that is to counteract the harmonic imbalance of a four cylinder. Though its only for noise and vibration it doesn't need to be there you might just notice more vibration around 3k rpms and 6500.
     
    Easter Bunny, via a mobile device, Nov 25, 2022
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  3. DR. K

    DR. K Greenie Member

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    It is a project for sure.
    My goal in having the rotating assembly balanced is to reduce some of the harmonics felt without the balance shaft assembly in place. #becausedaily. I guess I'm fancy like that.
     
  4. L337TurboZ

    L337TurboZ World Class Truck Squatter Greenie Member

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    I'm not sure what IC you're gonna run but I ran a Treadstone TR8 and it flowed a lot better than the small generic ebay IC it looks like you have now. I had originally bought the CX Racing piping and IC kit for my build. During pulls my IATs never dropped with the CX. Once going to Treadstone I saw temps immediately fall almost 20 degrees even in the summer.
     
    L337TurboZ, via a Motorola device, Nov 26, 2022
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  5. jdab555

    jdab555 Greenie Member

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    TR8 is a fantastic intercooler for the price, love mine.
     
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  6. DR. K

    DR. K Greenie Member

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    Screenshot_20221126_105914.jpg I'm planning to buy the S line from Mishimoto. It seems like a great value for a bar-and-plate core that is 23" x 12" x 3".

    When I first pulled the oil pan I found a mystery object sitting in the bottom, that I was not familiar with. This is my first 2.3l engine build of this DI era so I had to do a little digging to figure out where it came from. 20221118_090507.jpg

    It looked like a plunger for something exposed to oil pressure. I wanted to disassemble the oil pump for inspection anyway so I started there. It clearly didn't come from the oil pump so I moved to the VVT camshaft sprocket.
    20221119_105236.jpg
    20221119_104919.jpg

    There it is. It was from a prior VVT camshaft sprocket. The gen1 MS3 VVT sprockets were prone to failure and this is leftover from the original.
     

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    Last edited by a moderator: Nov 26, 2022
    DR. K, via a Samsung mobile device, Nov 26, 2022
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  7. DR. K

    DR. K Greenie Member

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    Tedious and gratifying. Purple Power with a brush and a firm grip for the win. 100K miles of poor maintenance leaves its mark.

    Not gonna lie, seeing that damn orange silicone between the transmission cases has me worried about this transmission... It's like the trademark of someone who doesn't know how to seal something up and probably shouldn't be messing whatever they use it on.

    Screenshot_20221127-163830_Gallery.jpg Screenshot_20221127-164406_Gallery.jpg Screenshot_20221127-164635_Gallery.jpg Screenshot_20221127-164446_Gallery.jpg Screenshot_20221127-164555_Gallery.jpg Screenshot_20221127-164622_Gallery.jpg Screenshot_20221127-164745_Gallery.jpg Screenshot_20221127-164732_Gallery.jpg Screenshot_20221127_185844.jpg 20221127_162906.jpg 20221127_160346.jpg 20221127_162915.jpg Screenshot_20221127-163957_Gallery.jpg
     
    Last edited: Nov 27, 2022
    DR. K, via a Samsung mobile device, Nov 27, 2022
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  8. StreetSpeed6

    StreetSpeed6 Diesel Slayer Silver Member

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    I still have a pile of boxes in my garage from doing the new top mount turbo setup with all new custom fabbed fmic I did. People overlook not only the work but the amount of $$$ in those pics lol

    Looks like you're doing it right man and props for it! Keep us posted on the progress and things are really looking great! Literally just did basically what you're doing now and it is VERY much worth it! Let me know if you have any questions along the way as I have a built motor and all that as well just went with a twin disc instead of the ACT.
     
    StreetSpeed6, via a mobile device, Nov 27, 2022
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  9. DR. K

    DR. K Greenie Member

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    Thank you for your kind words and encouragement. Once I'm up and running I'm going to put a monetary total by each section of my build list. It's good for people to see what goes into this stuff so they can make good decisions. I may start documenting my time also. These projects aren't for people who need instant gratification in everything they do. I'm the kind of person who needs to be on a journey to feel like my time is productive in life and my destination is a clear vision. Getting there also means I need to start a new journey, so I like to put a lot into the journey haha.
     
    DR. K, via a Samsung mobile device, Nov 28, 2022
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  10. StreetSpeed6

    StreetSpeed6 Diesel Slayer Silver Member

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    Lol I am not someone who necessarily needs instant gratification but sometimes I'm more on the lines of enjoy a bit of the journey, hate some of the journey, and then just glad I finally made it to the end of the journey to drive the dumb sucker hahaha
     
    StreetSpeed6, via a mobile device, Nov 28, 2022
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  11. Raider

    Raider Administraider Administrator Platinum Member

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    Raider, via an iPhone, Nov 28, 2022
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  12. DR. K

    DR. K Greenie Member

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    Thanks for the reference. That is a very nice write up. I'm tempted to open this gear box up and go through everything while it's out. I didn't get to test it when I bought it. I'm concerned about whoever was in it last based on seeing the orange silicone haha.
     
    DR. K, via a Samsung mobile device, Nov 28, 2022
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  13. DR. K

    DR. K Greenie Member

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    When looking at these flow specs on some common MS3 intake manifold options, it's pretty clear that JMF is what I need eventually. Considering how cheap I got the Focus ST manifold it's still worth installing and tuning with, at this point.

    Screenshot_20221205_153229.jpg
     
  14. StreetSpeed6

    StreetSpeed6 Diesel Slayer Silver Member

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    ST mani is much better/even flow than the stocker
     
    StreetSpeed6, via a mobile device, Dec 6, 2022
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  15. Easter Bunny

    Easter Bunny Professional Engineer Motorhead Platinum Member

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    for 500 hp i dont know that you really need more than the st manifold
     
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  16. DR. K

    DR. K Greenie Member

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    That's where I'm at with things. I am already starting to plan for the north of 500 HP in some ways, but I'll upgrade this later at this point.

    Some of this thought process sparked from second-guessing my turbo choice. I'd like to see compressor maps for the CST5 and the PTE 5858 for comparison. There are obvious differences in the overall power they can make, and I want to see maps to decide which one I'll be happier with overall, considering I will drive this daily. Thinking about peak power but also the torque curve. I know the 5858 will make more power, hands down. I just wonder if it'll have a more or less torque curve by nature.
     
  17. Sho

    Sho Silver Member

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    58 series pte is a badass turbo.

    Here's what my 5682 journal bearing did with a returnless system at 34.5psi.

    20180718_125159(1)-02-01.jpeg
     
    Sho, via a mobile device, Dec 14, 2022
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  18. StreetSpeed6

    StreetSpeed6 Diesel Slayer Silver Member

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    Curious to see where my gtx3576r lands me at the 30-35psi range. Hopefully similar to this!
     
    StreetSpeed6, via a mobile device, Dec 14, 2022
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  19. DR. K

    DR. K Greenie Member

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    I finally have my block back from the machine shop. After some deliberation about the precise measurement of the gauge point on these exact Manley pistons, I can now measure my piston-to-cylinder clearance! I ended up at .0034". It's not exactly where I wanted to be but damn close and I'm comfortable with it.

    Piston.jpg Set dial indicator.jpg Cylinder 1.jpg Cylinder 2.jpg Cylinder 3.jpg Cylinder 4.jpg
     
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  20. DR. K

    DR. K Greenie Member

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    I got the transmission pivot shaft seal, bearing and breather swap knocked out recently. I went through the Mazda dealer but these kits are also on Amazon these days. Amazon $50.

    Shift seal 2.jpg Shift seal 3.jpg

    Shif seal 4.jpg
     
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