Gt4 Engine Removal

[dawesy]

1st or second of april is ok. give us a bell when your coming over and ill make sure im in.

cant rmember what size the sandwich plate adapter is. fennies might know?

[Fawbs]

Ok dont think im gonna get the crane to you lee im afraid. However you will be glad to know ive just bought a load of shiny new stuff cause i got paid 2k this month for being in vegas. Literally got about 4 more things to get now.

[dawesy]

no sweat mate. when ever your ready. oh i do like shiney things

[Fawbs]

Right got a few pics this time as i didnt have much to do. This is the r/h drive shaft

As you can see the metal flange isn't up against the rubber, is this correct or does it need to be pushed in a bit more cause i cannot remember.

My gearbox cooler ive routed the two pipes either side of the radiator. Made some crude but effective brackets for the 2 coolers, few tie wraps on the pipes and to hold where the 2 coolers meet as it is sagging just slightly where they are attached bringing it close to the rad fins.

Ive looped the power steering pipes and taken out the cooler, will get a cooler in at some point in case i get track action in, just need to find one that fits the bill.

Just waiting on all my parts to arrive, with it being easter weekend it hasn't helped. Need to get a braided hose made up for the oil feed line to the turbo, only other thing is to get my downpipe modified well the only major thing.

[Fawbs]

dont know why those damn pictures arent showing but this is the album, first few pics

http://s698.photobucket.com/albums/vv343/cloqwise/

[dawesy]

looking good.

drivehaft will be fine, although check for leaks when its on the road as they often leak when disturbed.

everything else looks good.

there is a oil cooler off a transit van that works well as a power steering cooler, ill try and get a part number for you.

soon be fire up time

[Fawbs]

Yeh there really isnt a lot to do even though it may look like there is. Oh i got you some wire locking pliers lee, I managed to acquire two pairs haha

[dawesy]

cheers dude, let me know how much i owe ya ;)

[Fawbs]

Nowt mate, they were free i went in our tool locker and found loads of new tools, they were ordered about 3yrs ago and still haven't been etched up for use ha. Luckily there was 2 there so i got the other pair, i forgot to get the ezy outs i need tho :S

[Fawbs]

Right well, just at my parents at the moment. I decided to order an eBay manifold, i found the thickest was 2.7mm thick which is pretty good and ordered it costing 130 beans from 2fast2cool2. Ive had stuff off these guys before and they have been pretty good products so was expecting something half decent. I ordered the metal to make brackets to take the weight of the turbo so all was set until it turned up. The exhaust to turbo flange wasn't flat, the end of the pipes going into the collector were rougher than sandpaper and worst thing was that the exhaust manifold flange was completely and utterly wrong, the stud pattern was completely ****** up, i could not understand what the hell they had done, it was as if they had made the stud pattern back to front and even messed up the back to front bit.

So i'm sending that piece of crap back on monday and driving over to Calne to get the bridge in the standard manifold milled out. I'm getting a porting and polishing kit and doing it myself as luckily my dad has a dremel with a flexi drive. I've got some ceramic coating to put onto it.

Ive got my turbo feed pipe made up, new banjo fitting with 2 stainless hoses with a 4 way adapter in the middle. The 2 spare ports i am going to use for the oil temp and pressure sensors as the adapter is for 1/8npt fittings. I'm keeping everything simple using silicone hoses for the water feed and return and the turbo return hose.

The car is literally waiting in the wings, all i need is the header tank which is being made as we speak and the exhaust manifold which i will sort this week. As soon as we hit next month i will order all fluids and thats it, we are ready for start up.

Couple of questions - Which is the turbo coolant feed pipe, is it the one coming off the water elbow? Also do you think it would be best to attach the feed pipe to the lower water fitting as this would mean the turbo would be full to the brim with coolant at all times.

Also my swirl pot is connected to the radiator return pipe, does the lower port connect to the water elbow side where the flow is coming from or is it the other way round?

[KPARRIS-JONES]

Great work mate. Looking forward to it!

Shame about those stud patterns though. I hate pissing about with stuff like that... I never understood why they can't just get it right!

[dawesy]

yeah one of the turbo coolant feed pipes it the one on the elbow the other i think is on the pipe that runs to feed the heater.

wont really matter which way round TBH as there should be no air in the system so there will always be water in there.

also all i did on my manifold was knife edge the Siamese section on the turbo flange part and cut the bridge from the gasket worked a treat. i used a rotary burr carbide cutter in a die grinder only took 20 mins or so

[Fawbs]

After a bit of milling, going to get the grinders and polishers out now

[dawesy]

sweet!!. ill warn you that cast is hard.

[KPARRIS-JONES]

Nice work dude. I hate doing stuff like that, I simply don't have the patience.

Keep it up, I'm looking forward to seeing you fire this up even though I only hopped into this thread halfway through. :)

[Fawbs]

Ok just one or two things, just bare with me as i have never done this before. Right phil gave me a few tips on running the engine in, now i will my header tank etc all setup for the running in period. Now with everything that i have to cool the engine will this affect getting enough heat into the piston rings?

Ok another question is how do i plumb the wastegate in before i have my aftermarket ecu and boost solenoid???

[dawesy]

shouldn't affect it. just leave to cool as normal.

the pipe that would normally go to your actuator will need to go on the bottom port (one nearest the valve itself) then if you haven't got your boost valve setup then just put the other end of the pipe onto the fitting on the compressor housing, you will then run wastegate pressure (should be about 0.5 bar)

[Fawbs]

Yeh 0.7 i got so should be fine. Just been coating the manifold with cermakrome been a bit of a pain, first time i messed it up cause i the the metal was still damp but this time i managed to get 3/4 or more covered with a few areas flaking off. This last coat should do it, luckily only a little of it seems to go a long way, i must say from it being at 500degrees F it does seem to hold the heat in better but then again i'm not used to being near it when its boiling hot.

[Fawbs]

I think the only thing i have taken a chance on and that i'm worried about is the clutch as ive mentioned before. Managed to find a thread on where about 5 people have mostly used the stage 3 version of it on the gt4, all happily worked out well.

On various other cars the bad is about 60% the good is 40% but then again people dont usually post about the good that much. Most the bad stuff seems to come from the stage 2 version and to be honest you are always going to get problems with any clutch when enough people use it. If it lasts 6months+ i will be happy, i don't mind taking it out for a clutch change as i know what i am doing this time.

[dawesy]

i wouldnt worry. i had the helix clutch in mine for a while and did countless launches with no issues and it was only rated to about 360 ft lbs i was pushing over 380 through it. see how it goes. coming on well though.

no rush but when will you be able to get the engine crane back. making a start on mine very soon

[Fawbs]

sweet you moving it into the back? You in during the day this week?

[dawesy]

im not but me dad only lives across the road so you could drop it there. i can leave your deposit there as well. let me know what day your thinking of and ill give him the heads up.

yeah finally time to get cracking, hope it dosnt take too long to do cos want to have some fun in it this year

[Fawbs]

What you going to do, i mean what comes to mind is the drive shafts, will they fit the corolla hubs? When you cut through the boot how you going to seal it from outside when the engine is in?

[Fawbs]

Ok this is how the car is at the moment, only really needs the turbo installing which is pretty straight forward, just need the adapter which is on its way. Dan i checked the driveshafts, when u pull them they move say 10mm+ but dont come out and wont go any further, is that correct? My oil cooler (blue one) one of the fittings on it is ****** wish is annoying so i need to replace it.

Ok got my header tank today, looks quite swish, probably going to make some hanging brackets from the left hand suspension turret and mount it there. Cost me 79 quid to get it made. I don't fully understand the innards of the screw cap, did my own pressure test on it. When all ports are blocked apart from the one i blow in the pressure builds and stays pressurised, i think, however when i suck air in it draws air in from the screw cap. i'm guessing this is for when coolant leaves the tank, just thought it was a bit confusing cause i read up somewhere that the screw cap type vents pressure out from the crap.

Also got my mr2 turbo rev 3 throttle body inlet from japan, looks in good condition, will put this on tomorrow.

[Fawbs]

Right thats the position i'm going for, going to make up some brackets tomorrow. One point of the tank will contact the body work so i'm going to prc some sacrificial plates onto the tank and body.

Picture of the mr2 throttle inlet. Lee do you need any gaskets for the 2 bits? None came with them like