S5 rebuild that went from bad to worse
 

I have a 90' vert that wouldn't start. There was a reason. Now Banzai racing has it turns out Front apex seal broke trashing front rotor, housing and front iron(busted cooling jacket). Rear rotor had side seal imbedded in it and ruined rear rotor housing. I let it set in storage for over a year and it all rusted result new engine needed. Here's the link if you want to see pics. www. Banzai-racing.com/2014_
customers/miracle_breakdown.htm

Here are some pics from the beginning.

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I will keep adding pics as teardown and rebuild happen.

Teardown pics engine had no usable parts. Notice broken coolant retaining wall and trashed rotor.

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Core engine I bought supposedly ran we doubt it. If it did not well.

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Not what I hoped for. Irons and rotors were usable. Housings not so much.

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So at this point we have went through 2 sets of irons, 4 rotors, and 6 housings to get to this point.

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There is light at the tunnel!

Some pics of new top.Tried selling it a few times but no takers. Can't wait to drive it again!

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My budget rebuild kinda been shot out the window.

My custom CAS cover I made should be a good finishing touch when Banzai finishes engine.


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Me and my friend were setting around wondering if his laser etching machine would work on a stock CAS cover and it did. Going to try a red billet CAS cover next.
I will post a pic when done.

Here's the custom red billet CAS cover we made. Bought the blank of eBay and used my friends laser to
etch it. Tell me what you think. The last piece to go on rebuild.....will have my car in a couple days I hope. oh I can't wait.

Should I remove 5th and 6th ports while I have the chance?

Should remove 5th and 6th port sleeves, actuators and smog pump on a daily driver? Nows my chance if I'm going to do it?

Depends on what your plans are with the car. If your trying to extract every bit of power at the top end then yes. However, the stock systems do a great job of providing more torque and power lower down in the rpm range and removing them will result in a noticeable loss. If its a streetcar that you dont plan on porting I personally would leave the stock systems in place. When I fixed my intake manifold to function as intended i was rather surprised to FEEL such a difference in the way the car behaves and revs.

Both actuators were seized when Banzai tore it down so sleeves were never opening.This is my first s5 just going to be a daily driver with a few mods. Wish I could drive one with and without to feel the difference before I say yes or no.

unless your scrapping the entire existing manifold for an ITB setup, it will always be a restriction when it comes to making power. afterall you need the LIM gasget whether you delete the actuators or not. It's not like you cant hook everything up and decide when your car is running. Its really not too much work to get it off once the gasket is fresh and its not seized from sitting for more than a decade.

Play smart. Alot of people make dumb decisions once the engine is out and they figure they should go crazy and change everything. The only Thing you cant change once the block is in is the porting of the engine. Intake and exhaust can all be done in good time.

Ok is it better or worse internally on engine to remove sleeves? Porting is not an option and this point short block is ready. Here are some pics

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Hope to be up and running in next couple days!

You wont be harming the engine by removing the 6 port sleeves unless you leave something in there like a nut or bolt

Also I should of mentioned we built the motor with T2 housings so there should be no exhaust restriction like on n/a housing with diverters.

The 6 ports work great on my GSL-SE can't Imagine not taking advantage of the system. When I installed my Racing Beat Header and system I pulled the intake, cleaned the port sleeves installed Pineapple inserts, and cleaned the port runners in the irons till they were spotless. Was super easy to do. That was 15k miles ago. They still work perfectly, everyday I drive it. Its my DD. Low end power is is so much fun intersection when driving around town. Then when the ports open you get a good kick, and the ass end starts coming around. They also worked flawlessly on my 86 till the coolant seals let go.

What is the big hype about pineapple sleeves compared to stock sleeves? Mine were full of carbon and seized. We believe that's what broke loose and trashed rotor and housings.

they smooth out the airflow path. Atkins Rotory makes a one piece sleeve. Yours were seized
because the PO never drove the car hard enough to keep them loose or some connection came loose

One day closer long block complete block off plates and new clutch, pressure plate etc. installed.

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Got it dropped in and tranny hooked up. Won't be long now......

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Here's the good news it runs like a champ. They did a great job. Since the car blew up shortly after I got it now I'm finding all the little things that were wrong with the car. Are front wheel bearings pressed in? I will be changing them asap.

Front bearings themselves no, the bearing races though can be a problem. When I did mine the spare 150k hubs had really good condition races so I did bearings only.

Thanks for the info.

Any ideas why? Here is a new one if I turn on my headlights the idle increases @200 rpm and the engine runs smoother. New rebuilt motor less than 500 miles it's not a motor issue.

Probably because the ECU is detecting load created by the headlights being on and the BAC is supplying more air to the engine thus a small increase in the rpm. The BAC will attempt to keep the idle from dropping below 750 rpm.

Satch is correct.

The BAC kicks the idle up when the headlights, rear defrost, A/C, etc. are turned on.