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Old 07-25-2007, 11:20 PM   #30
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Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

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Day 9

Start time: ~5:30pm
End time: ~10:45pm

Dan finished up my oil pan a day early!
I'm quite happy with how the return tube turned out!
I ended up trimming it down about 2".

Today I got the oil pan reinstalled, and that's about it.
Cleaning the old oem RTV off took a while.
I cleaned the gasket surface about 3 times with mineral spirits before applying the new RTV and installing the pan.
The Haynes manual states to remove the transmission in order to remove the oil pan. I did not.
It was a tight fit, but it does come out and go back in without removing the tranny.
The only concern would be proper sealing of the pan against the timing cover.
I suppose I'll find out soon enough if I did it correctly. Seems ok at first glance.

I started removing the intake manifold.. man what a pain.
I'm revamping the stock PCV system so all air is from and back to the atmosphere.
That way the cruddy oily fumes won't gunk up my intake tract and at the same time throw off my tune.

Assumming all goes well my tune date is Friday August 3rd!
I plan on working like a mad man this weekend to get the car completed.

What's left (off the top of my head):
- Exhaust from the cat back, using mandrel bends but nothing is welded or cut to length yet
- Reassemble "good" turbo
- Route oil feed a return lines
- Splice into coolant lines and route to turbo (one of the last things I do)
- Install gauges and route lines. (Boost and Oil Pressure)
- Redo PCV system
- Reinstall and clamp intercooler piping
- Install base "no boost" tune


Oil pan with drain tube:
Before trimming the tube.
It's slightly below the oil line.

Pan with baffle installed:

Oil pan installed:

A couple of random pics of the test-fit turbo from beneath the car:

2006 sonic blue zx5 GT2871r turbo.

Last edited by sporadic; 09-05-2007 at 11:09 AM.
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