Photo by Duane Uyeda

Project Mitsubishi Lancer Evolution 9 – Part 14 – Engine Failure

It’s finally happened. After all the testing, events, street miles and races, Project Evo IX’s heart has given out. We’re all bummed here at OR that we’re going to have to rebuild an engine using a budget that we didn’t anticipate but our 4G63 engine has lived a long life.

This particular Lancer Evo 9 was born as a Sport Compact Car magazine project car, back when I used to head up the publication and before its untimely demise. From those days on, this trusty Mitsubishi saw the skidpad, figure-8, drag strip, road course, autocross, track days and time attack competition. All the while, it was a daily driver and saw regular street miles as well. It’s lived a good life. Let’s just say this, if it was a rotary–powered RX-7 or E46 M3, the engine would have exploded in grand fashion about 30,000 miles ago.

The road to our failure begins at the 2009 Super Lap Battle Finals event. Fresh off of an overall victory at the Evo vs. STI Shootout, we stayed at the beautiful Motel 6 in Buttonwillow, California and awoke the next day for the Super Lap Battle time attack event. Upon arriving to Buttonwillow Raceway, Albert and I were ready to set up. Stickers needed changing, tires needed swapping and brake fluid needed to be bled out. From all the commotion in the pits, it was obvious that we weren’t alone. As the biggest time attack event of the year, the Super Lap event attracted the likes of Sierra Sierra Enterprises, FXMD, AMS, Hasport, Evasive Motorsports, Robispec, TEIN, KW, StopTech and Crawford Performance. Everyone was busy doing a morning concoction of wrenching, swearing and waking up.

The previous day, at the Evo vs STI Shootout, Project Evo 9 showed some serious speed. Fastest time of the day for us was a 1:59.3. We made the switch to KW 2-way motorsport coilovers, a Carbonetic rear limited-slip differential, TTech 600 turbo and a Gruppe-S ACD ECU. We drove it to the track, slapped on our 340 treadwear Continental tires and demolished the Porsche 911 Turbo’s lap time.

Project Evo 9 - brakes bled, Nitto NT05 tires mounted and ready to rock

Even after a few sessions on track, the NT05 tires handle the heat well, no tearing of the tread

With the weather nearly identical to the previous day, we were eager to switch to our 200 treadwear Nitto NT05 tires and see how faster we could go. Our early predictions were that Project Evo 9 would be running in the 1:57 range, with a high 1:56 possible if we got our adjustments just right. In case you haven’t noticed, that’s flying folks. We’re talking about a full weight, full interior, street legal car on genuine unshaven street tires being able to keep up with a supercar level machine like the Nissan GT-R. Even we didn’t think it was possible until we hit the track.

Many street shocks or coilover setups only adjust rebound (Koni Yellow) or adjust rebound and compression together (just about every low- to mid-level coilover setup). If the shocks are custom valved or tested to have the correct damping range, then they can work great on the street and the track. We’ve had great success in the past building street and weekend track cars using off-the-sheld shocks from brands like Koni, Tokico and TEIN. But when it comes time to split hundredths in real competition, having independent compression and rebound settings is a major plus. Just take a look at Koni and TEIN’s upper level products, such as the 8611 and SRC, respectively.

Project Evo 9’s KW motorsport coilovers allowed us to soften the compression for the NT05’s stiffer sidewalls without compromising our rebound settings. Vice versa, if we wanted to adjust our rebound damping, we didn’t have to sacrifice the car’s body roll resistance. Our only gripe is, after about the third time crawling underneath our blazing inferno of a car with a tiny hex key in hand, we wish the compression adjuster was easier to use.

Continue to Project Evo IX - Part 13 - Evo vs STI Shootout >>>

Evo 9 fast lap data on Continental Extreme Contact DW tires

Project Evo 9 on track - Photo by Duane Uyeda

With tire pyrometer, lap timer and pressure gauge in hand, we were ready for Russ after the first session. We had spent most of our early practice playing with shock settings and tire pressures and Russ reported back that the car felt great, even faster than the previous day. The lap timer read that we were now 0.5-seconds slower than the previous day. An easy win refusing to drop right into our lap. Surprising.

The results were puzzling. Russ reported back that the Nitto NT05s seemed to display much more grip than the Continental ExtremeContact DWs and the car’s balance felt great throughout the course. No issues with braking, curbing contact, turn-in or corner exit. The car just felt better and went slower.

As we were in the midst of adjusting Project Evo 9, one of competitors came by to pay a visit. Jon Drenas from HB Speed had showed up to the Evo vs STI Shootout and decided to stay for the Super Lap Battle event, since he had already driven himself two hours into the dusty California desert. With only the Continental tires left on his Lancer Evo X, he was unable to place higher than 5th. Drenas spotted our practice set of Nitto NT05s sitting in the sun and asked to use the set for his next run session. Since Project Evo 9 had run faster on the same Conti tires, I was interested in seeing how his car would respond to NT05s.

After a few laps, driver Billy Brooks, from Mode Racing, was able to drop the HB Speed Evo X into a 1:57.6 lap. This turned out to be more than 4-seconds faster than the Evo X had been running all morning, putting the HB Speed team into second place and bumping us off the podium into 4th. With the compression on our KWs softened up, Russ headed out with Project Evo 9. In just a few minutes, he came coasting back into the pits. The outlook was bad.

Exiting the Esses at Buttonwillow Raceway - Photo by Duane Uyeda

Project Evo 9 heading up the Buttonhook - Photo by Duane Uyeda

Russ reported a sudden loss of power and a puff of smoke out the back of the car. He wisely shut off the engine and coasted Project Evo 9 all the way back into the pits. Luckily, he was nearly in front of the pit entrance when the failure occurred on track. Maybe this is why we couldn't go faster all day.

After inspecting for gushing oil and odd holes in the engine block, we tried to fire up Project Evo 9. After one crank, the oil dipstick shot 6-feet into the air and oil blew out of the dipstick tube. We knew then where the oil for the smoke came from. Our day was done, we would end up in 4th place Street AWD at the Super Lap Battle Finals. We haven’t tried to fire up our Mitsubishi project car to this day.

In honor of their elevation to 2nd place, Billy and Jon agreed to tow the stricken Project Evo 9 back towards Los Angeles. The HB Speed Evo X, which was towed to the track, would be driven back by Jon himself, after a full topping of E85 fuel. Billy would then be able to help tow us back inside the Mode Racing trailer. At least it all worked out in the end.

A later diagnosis by Tuning Technologies revealed zero compression in cylinder four and a missing spark plug electrode. Our 4G63 engine is kaput. For now, Project Evo 9 has been sidelined, the first time that it has ever sat off the road. We’ve been bouncing around ideas with Tuning Technologies as to what direction we want to go from here. The engine will either need to be swapped out or rebuilt. We’re obviously leaning towards new internals but haven’t arrived at our perfect formula. For now, we’re just saving our pennies.

Sources

ENGINE
Tuning Technologies – TTech 600 bolt-on turbocharger, custom ECU flash, engine parts installation labor
(909) 783-1200
www.tuningtechnologies.com

GReddy – SP2 catback exhaust, PRofec B-spec II electronic boost controller
www.greddy.com

Works – O2 housing, downpipe, high-flow catalytic converter
(415) 226-2500
www.worksevo.com

K&N Engineering – Oil filter
(800) 858-3333
www.knfilters.com

AEM – CARB-legal cold air intake
(800) 992-3000
www.aempower.com

SUSPENSION
KW Automotive – 2-way motorsport coilovers
(800) 445-3767
www.kw-suspension.com

M1 Fabrication & Development – chassis setup, alignment, carbon fiber front splitter, harness bar, brake lines
www.m1fd.com

WHEELS
5Zigen – 18x9.5” +35 offset FN01R-C wheels
(310) 608-5575
www.5zigenusa.com

TIRES
Nitto – 265/35/18 NT05 high-performance street tires
www.nittotire.com

BODY
INGS – N-Spec Hybrid Aero front bumper, side skirts
www.ings-net.com

APR Performance – Rear carbon fiber wing, carbon fiber diffuser
(909) 594-3796
www.aprperformance.com

DRIVETRAIN
Carbonetic – carbon rear limited-slip differential
(310) 635-3555
www.carbonetic.net

Gruppe-S – ACD ECU flash
www.gruppe-s.com

INTERIOR
Buddy Club – Super Low Down Seat Rails
(909) 923-9188
www.buddyclub.us

Our Nitto NT05 tires helped the HB Speed Evo X take 2nd place. And helped us take 4th instead - Photo by Duane Uyeda

Russ - "Quick, get over here!". Me - "Why's he going so slow down there?" - Photo by Duane Uyeda

The smoke came from the Works downpipe, which burned off oil that got shot out of the dipstick tube

For now, Project Evo 9 sits at Tuning Technologies, waiting for its next life

Continue to Project Evo IX - Part 13 - Evo vs STI Shootout >>>