Trilogy Project

[Dennis Reinhart]

Over the next few weeks we will be working on Larry's car along with this we have a 03 Trilogy the car has a burnt valve on cylinder # 5 the intake is full of oil I plan on pulling the engine and heads, and doing a complete photo shoot we will be adding the IAT mod a BA300 Maf and my CAK and retune the car.

 

[SC Cheesehead]

Over the next few weeks we will be working on Larry's car along with this we have a 03 Trilogy the car has a burnt valve on cylinder # 5 the intake is full of oil I plan on pulling the engine and heads, and doing a complete photo shoot we will be adding the TAT mod a BA300 Maf and my CAK and retune the car.

will be interested in following this, Dennis. Any thoughts on the cause of the burnt valve?

 

[Dennis Reinhart]

will be interested in following this, Dennis. Any thoughts on the cause of the burnt valve?

The intake was full of oil. I will install seperators on both lines if the bottom end is good.

 

[Dennis Reinhart]

The car is a 03 and has about 80 K we did a leak down and we hear air out of the tail pipe and # 5 is down.





So will pull the engine and put it on a stand and take the heads off, if the pistons are good will send the heads out fo a good valve job, I will install the IAT and re'tune the car.

 

[Dennis Reinhart]

Today we got Matt's engine out and on a engine stand, and we got the heads off and I was gladd that my suspecion was confirmed it is a bat seat on cylinder #5 both head will go out to be tested and resurfaced, his car is a 03A and it does not have the good head so the machine shop will determine if it can be reused or not, I do have a set of 04 heads here.

I used a flashlight to show the results

After they come back will install head studs and new gaskets I will do the IAT mod to the lower intake and retune the car.

 

[Dennis Reinhart]

As I had posted earlier Matt brought his car by with a lean code and upon examination and cylinder leak down test we found cylinder # 5 down to 75 pounds normal compression is about 150 lbs. so we removed the transmission and engine, installed the engine on an engine stand and we removed both cylinder heads and sure enough we found a burnt valve on cylinder number five.

Upon engine tear down I found a 90° rubber hose coming off the back of the supercharger that connects to a steel tube that runs to the PCV valve it had deteriorated with age and had a small hole in it.

I replaced this with a piece of 90° heater hose; this is much thicker and will be less prone to rotting and deteriorating with age. Today we received both cylinder heads back from the machine shop and they did an excellent job they look brand-new, they replaced the seat on cylinder number five exhaust valve replaced all the guides all new valve seals disassembled and cleaned all the lifters.

We thoroughly cleaned the block there was a heavy deposit of carbon on top of all the pistons. We installed new fell Pro head gaskets and head bolts.

Next we installed the timing chains.

We next installed the timing cover both valve covers and installed a set of brisk Spark plugs.

If you will look in the previous pictures you'll notice a large amount of oil in the upper intake once we had pulled the supercharger and the inner cooler we found the lower intake also had a large amount of oil in it, so we thoroughly cleaned that and drilled and tapped hole from the new lower intake air temperature sensor.

 

[Dennis Reinhart]

Part 2

Before installing the lower intake and supercharger we installed our new rear cylinder head cooling kit.

I also wanted to show you what has to be done when installing the Eaton's on the marauder motors, as you can see the intake Valley both knock sensor bosses have to be ground down to clear the lower intake and you have to remove the knock sensors if you have an 03 marauder it has one knock sensor if you have an 04 marauder it has two knock sensors, in my opinion relocating the knock sensors to the back of the cylinder heads is useless I would just unplug them and turn them off in the tuning software.

Now upon reassembly of this engine something caught my eye when we were installing the lower intake, I have no idea if all the Eaton's are the same, all I can say is that I made several phone calls today and talked to the top people that I know in the country and what I found out today I am absolutely confident in that the way the vacuum hoses are plumbed in the back of the supercharger are wrong. First of all let me show you a picture of what we found today.

The lower intake has a vacuum port threaded into the bottom of the intake, now the lower intake on these supercharger is where the inter cooler is located and this is where boost is distributed to the individual cylinders, everything located in the lower intake is boost sensitive. There is a 3/8 vacuum hose routed from underneath the lower intake that comes up to the back of the supercharger and connects to a tee fitting that tee fitting goes to the stock marauder PCV valve and also connects to the upper Plenum of the supercharger where the fresh air is drawn in to the impeller on the supercharger this is blowing boost in the upper plenum as well as the PCV valve.


As you can clearly see this fitting is located at the bottom of the lower intake this is also where any oil collects so you're actually going to blow oil out of the bottom of the intake into the upper Plenum and boost into the PCV valve now the Eaton kits utilize the stock OEM marauder PCV valve, this PCV valve is not a check valve so in essence you are blowing boost into the passenger valve cover. So what I did is I removed this fitting and I installed the plug, look at the next picture and you can clearly see what I'm trying to describe.

 

[Dennis Reinhart]

Part 3

I connected the PCV valve directly to the upper Plenum center vacuum port and capped off the tee fitting, we also installed an oil separator in between the upper Plenum and the PCV valve.

Now once we had repaired the vacuum routing we installed the lower intake and supercharger, the next thing we did is remove the single boost sensitive port located directly at the back of the supercharger it's critical that the fuel rail pressure sensor be connected directly to a boost sensitive port below is a picture of the stock boost port.

What we did here is we added a new fitting with twin ports so one port can go to the fuel rail pressure sensor, and the other port can go to your boost guage.

I honestly feel that with these small corrections the car absolutely should run better and probably develop more boost if anything it's going to cut down on the amount of oil that's going into the intake you will no longer be blowing boost into the PCV valve or the upper Plenum and these are all very simple corrections that can be done for anyone that's doing in Eaton kit or upgrading a trilogy kit with the new IAT and a boost sensitive fuel rail pressure sensor. I worked on this for hours so if I made typos bare with me and I hope every body likes this and shares there inputs as well, and every one have a great weekend.

 

[bugsyc]

Thank you Dennis for posting all the pictures and comments on this rebuild...Super info...All personality nonsence aside,you definetly know Marauder engines like no one else...Looking foward to next installment.:bows:

 

[Dennis Reinhart]

Here is the shots showing how I feel it should be routed, this will prevent any boost going to the PCV valve as well as the upper plenum the oil separator will not allow oil to be pulled through the PCV and I am going to install one on the T/B side as well.

I will have the dyno sheets later this week and a video I want to thank Matt for bringing the car here.

 

[Dennis Reinhart]

Matt came by today,we will be installing this on Monday I hope eveyone has a good weekend.

 

[RacerX]

Nice information Dennis! Thanks. One question though. Isn't the stock FRPS boost and vacuum sensitive or do you need a different one? I thought the 03/04 Cobra was the same as ours. :dunno: :2thumbs:

 

[Dennis Reinhart]

Nice information Dennis! Thanks. One question though. Isn't the stock FRPS boost and vacuum sensitive or do you need a different one? I thought the 03/04 Cobra was the same as ours. :dunno: :2thumbs:

The 03 Cobra FRPS has allways been boost sensitive, and the sensors are the same.

 

[Seneca]

nice info and a good read ty dennis

 

[ridinclean]

Looking forward to seeing the results Dennis..thanks for the thorough write up

 

[ctrlraven]

Nice write up, I feel like I learned something new today. lol

 

[FormulaMarauder]

Awesome work as always, Dennis

 

[Dennis Reinhart]

Matts engine is in I am also putting a oil seperator on the drivers side as well, I pretty much have a full shop we have five Marauders all under construction Larrys SC should be here tomorrow, a nice man is coming in for a 1500 upgrade we have three Cobra crate motors, so we are very busy and trying to get these out as soon as possible, I should have Matts on the dyno tomorrow. What would be nice is see a comparison using a alluminator and I am sure that will happen and we are doing a six speed conversion for a local Marauder owner.

 

[Dave Compson]

Looking forward to seeing the dyno results.

Nice writeup.

 

[Dennis Reinhart]

The car is on the dyno and we have found another issue, again I have no idea who installed this kit. I do know that the BAP was wired totally wrong, it was wired after the FPDM when done this way the PCM has no controll over the fuel pump. It has to be wired before the FPDM the output of the inertia switch is the input to the FPDM so this would be the the input voltage to the BAP the out put of the BAP goes to the FPDM then the out put of that goes directly to the fuel pump, this BAP was wired after the FPDM then to the fuel pump and it also had the boost switch that turns on the BAP when it sees boost. I bypassed this as most other shops do. So the BAP is active all the time, and this car had the STOCK OEM fuel pump that has now been changed to the GT super piump I will post pictiures and dyno sheets and data logs later. Below is how it should be done. Again I am just trying to show how things work. Have a graet weekend.