[Mk2] [Turbo] My Engine Rebuild

[LuizeGT]

Engine coming soon so want go sort my "plan" out.

going to strip and rebuild with a toyota seal kit. metal headgasket and new bearings etc.

what headgasket size do i go for? its a rev2 engine which is fine and bought for transplant but i bought instead, minimal skimming i am hoping.

forged pistons.... 86.5 or 87? wiseco or JE?

what do i do about valves? for my power aim im not going to need uprated or anything but what do i need to do to get them like new?

would a rev3 inlet manifold fit ok to a rev2 head?

remove tvis? i need to make a mounting plate?

il be getting a GT series turbo to bolt on,hopefully with external wastegate. keep stock manifold?

new water and oil pump

what about crank, should i get that reground or anything like that?

im going to paint the block and gearbox etc silver, what paint should i use without it peeling?

ANY help and advice will be great!!

[TUBBY-DEUCE]

go for the smallest diameter piston you can get away with, this will depend on how much the cylinder has to be machined. (hopefully as little as possible)
standard valves are good for alot of power.
and depending on the crank you should get away with a polish.
it all depends on what condition the block, cylinder walls are in etc.
so you wont know untill you get dirty and start stripping

[LuizeGT]

quite looking forward to ripping it apart haha! so pref 86 or 86.5

[cantfindausername]

head gasket should be calculated from the stock size plus any material that has been skimmed. Assuming you want to keep the stock CR.

Pistons, 86.5 CP get my vote.

Valves - just make sure they're cleaned and ground in properly.

Dont think the rev3 manifold will fit a rev2 head. Could go straight for a rev3 head and HG accordingly. If you keep the rev2 manifold and want rid of the TVIS I have a gutted one thats coming off my car. Timescale dependant - should already be off though.

As said above, just touch the crank. Get it straight checked and crack detected too.

Hammerite is a favorite on the engine. Engine enamel is better on the block from what I've seen, but spray silver on the box came out a treat on my mates Honda.

[sanchi]

quite looking forward to ripping it apart haha! so pref 86 or 86.5

I've got 86.25 cp pistions in mine!

[prosser]

im going same route as you so im going to follow this post i was going to clean the gear box up and spray it with some silver hammerite like this
http://s254.photobucket.com/albums/hh11 ... earbox.jpg
looks good
and has any one got any pointers about rebuilding it myself i would love to do it myself does anyone know the torque settings ????

[LuizeGT]

wow that looks good!!

ive got access to my works workshop books on the 3SGTE so il post up all the torque settings u need. il post up as i go along and maybe make a "how to" on it lol

anything you want to know just ask and il look it up

[Martin F]

ive a rev3 cylinder head and inlet manifold if your thinking of going that way...

what are your power goals, the pistons are the most expensive part so im guessing your going for some decent power, like 400 bhp+

amazing feeling having that much power so if you haven't considered it but are going down the forged piston route then think logically/think again

i know, me bad

[cantfindausername]

Rods aint cheap either. But then a complete forged build is never done as a "Cheap alternative"

Prosser, all the torque settings, and how to do things are available in the BGB. Here is an online version: http://mr2.johnwoo.nl/bgb/

[prosser]

thanks for that

[marcnoonan]

Hi Louise,

Sorry can't help with the build Q's, but







I did some research on the detailing websites and used Simonize 5 Star silver wheel paint. Heat resistant to 200 and very solvent resistant and best of all.....easy to use and cheap. As an added bonus it's the same colour as the aluminium of the head in the third pic (heads not painted at all). I just cleaned everything up with brake cleaner, washed down with washing up liquid and then painted once dried. Everythings had three coats of paint...even the individual nuts.

Hope that helps get it shiney!

Good luck

Marc

[cantfindausername]

Yeah thats good stuff that is. I did some of the Ally work on mine with that. Inlet manifold etc.

[LuizeGT]

whats the deal with stroker kits? looking at the one on xxxx in a 86.5 piston size. did see the JUN ones that do a 3.2 stroker or something but cant afford that haha.

works out a bit better for a stroker kit

[LuizeGT]

guess a stroker is a no no? lol

ok i think im going to aim for 400bhp or as close as i can get.

i currently have link g3 ecu so that should be ok for it.

im looking at forged pistons
metal HG
con rods ???
ARB bolt kits wherever i can put them lol
lightened flywheel?
GT series turbo (which one?)
800 or 1000cc injectors?? sard?
wolfkatz fuel rail?
sleve the block?
6 puk clutch? currently got exedy stage 1 so that will be usless
will my walbro be ok for fueling?
uprated knock sensor?
cooling....... currently have a side mount with spal and lid fans, dont really want to go for a boot mount as i use my boot and dont really want st205 charge cooler. are there ANY sidemounts that will do it with the aid of water injection or is sidemount just a no no?

just starting to price up, remember i have a rev2 engine to do this with, i want this reliable and really dont want the engine out again so if theres ANYTHING i really need for this build then il do it now.

[cantfindausername]

forged pistons - yes
metal HG - yes
con rods ??? - yes
ARB bolt kits wherever i can put them lol - yes
lightened flywheel? - yes
GT series turbo (which one?) - yes GT30xx
800 or 1000cc injectors?? sard? - 800cc
wolfkatz fuel rail? - yes
sleve the block? - no
6 puk clutch? - yes, uprated, but shop around for one to suit power levels.
will my walbro be ok for fueling? - yes
uprated knock sensor? - no
cooling....... currently have a side mount with spal and lid fans, dont really want to go for a boot mount as i use my boot and dont really want st205 charge cooler. are there ANY sidemounts that will do it with the aid of water injection or is sidemount just a no no? - yes possibly ARC, HKS or GReddy, they should all be ok for that power level.

[Extubby]

I thought that std rods were good for 500bhp?

[TUBBY-DEUCE]

I thought that std rods were good for 500bhp?

yes but they are heavier, why skimp out , plus less rotational mass is good for more responsive engine , i think thats right

[cantfindausername]

I thought that std rods were good for 500bhp?

yes but they are heavier, why skimp out , plus less rotational mass is good for more responsive engine , i think thats right

Exactely.

Flywheel must be good for high horse power too, but you'd never leave that in there to weight things down. Why do half a job?

[LuizeGT]

yup, thats my thinking. i want to do it properly and once only. eagle rods any good? theres a good package from the usa which works out 500 delivered for wiseco pistons and eagle rods or should i stick to JE pistons?

going for oversized valves too, any recommendations?

[sutton]

I heard JE are prone to slap, try cp pistons, alot of people rate them on here, i'll be using them on my build