few more bits done today finished the turbo clocking bracket



this is my 1.4bar actuator



all fitted ready to go



then I have started to redo the intercooler pipe work


managed to get rid of 3 90degres bends and replace them with 45degre bends


need to get the engine back to gether then i can finish the pipe wokr off

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BRD Page

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Great stuff... removing the 90 degree bends will certainly help with flow

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Great to see the progress in pics.The pipe runs look very good

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

hoping to have it all rehoned and rings gaped and pistons fitted tomorrow

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ok had a good days work on the car with the help Dug big thanks mate
first we set up the ring gaping tool


we did a trial test with an old ring




so onto honing the bores forgot to take photos as we were honing out the bores but as you can see all done and ready to set up ring gaps



cheeking the gap on the rings

so we go the top ring for piston 1/2/3/4/5 and placed it in the bores to see what the gaps was



using the piston to push ring down into the bores so we could get the right gap





we had to gap 2 of the rings to get the right tolerance



then build up the pistons


then after doing this to all 4 piston’s refitted them to the block




than is was onto fitting the head and torque everything up




than time to fit cam belt and set timing up
not shore what Dug is doing here lol



then re fit exhaust manifold and turbo



I have just dropped the cam cover in place for now to keep it all clean


if the weather is good tomorrow I’ll be out and should have it nearly all back together

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BRD Page

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Interesting ring gap tool! I've only ever gapped rings using a flat file on the ring ends. No pics of the bottom end but I guess you just re-assembled the big ends from the bottom using the original shells? Top effort doing all this with the engine in-car

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

yes just re-assembled the big ends from the bottom using the original shells, to be fair its not that hard a job to do in the car by using the ring gap tool you can make shore that you take the same amouht of each side of the rings and is very easy to use

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BRD Page

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Great effort! Thanks for taking the time and trouble to post pics to help everyone!

Bet you were pleased the sun has been out today! It's much nicer doing these jobs when it's warm!

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Was a real nice day with the traditional Bacon sandwich for work done.

Tbh this was.the easiest engine I've put rings in most were.within spec out the box, lucky I guess

At least now it shouldn't smoke and should be a.healthy engine. Original ring gaps were way to big...

was a good day a few more photos 1 of my other mates took

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BRD Page

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ok done some more work today but been very busy so no many photos
got the sump and everything on and in place



then started on the wiring and fuelling



then refit ally rad




only problem I have had is that 1 of the cables for the plus had broken off



it’s the plug that goes to the cold start sensor I think
.

as you can see not much room when turbo is clocked


and I am now at this stage

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BRD Page

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a nice day and some morw work on the car done

finished the new cold side of the intercooler pipe work
hade to make some new pipes up using my little tool









so now i have her to this stage


all i have goto do now if sort out the hot side witch is now going to be easy as there isent much room witcha 52mm rad in the weay:(

on a good not i managed to fix the plug
solderd in and fix 2 new wiers to the pulg


then sealed it all up job done


should have new crank pully mid week so hopeing to fire it all up the weekend:D

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BRD Page

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ok got a bit more done to night managed to fit the pipe work for the clocked turbo to intercooler


as you can see not a lots of room






all piped up now

just goto add oil and water tomorrow then it should all fire up

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BRD Page

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only thing i rely need now is crank pulley or will the 1 i have with a small chip in it be ok?




will i be ok to use this to start it up nad make shore every thing is runing ok?

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BRD Page

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ok good bad day finished al the piping and filled with water and oil all good then cranked it over for about 5 mins to get oil round the engine, bit I noticed that the oil light wouldn’t go out or the oil pressure gauge did not show any thing so need to investigate, there was oil getting the take of plate on the block but not getting up the head so there was only 1 thing to do, strip the head off and have a look as I was wondering if I had fitted the head gasket the wrong way round so off came the head only took me 2hours I think may be quicker

and as you can see the head gasket was the wrong way round not letting the oil into the head




iv called it a day and having a rest now ready to rebuild the egine tomorrow again lol

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