JLee's 1991 Toyota MR2 Turbo build thread

[jlee]

ATS Racing 1200cc injectors are on the way.

A Wiseco ring compressor is on the way.

A Jegs piston ring filer is on the way.

w00t.

 

[XavierMace]

And there was much rejoicing.

 

[jlee]

Fresh and clean!

 

[JCH13]

Awesome!

 

[jlee]

 

[exdeath]

Shineeeeeee.

 

[FuzzyDunlop]

It's... So.... Beautiful!....

 

[ino uno soweno]

Very Beautiful head too,


You do nice work Sir, :thumbsup::thumbsup::thumbsup:.

 

[jlee]

Checked main bearing clearances with Plastigage:

Cap #5: almost the middle of 0.025mm to 0.038mm, erring on the larger side (maybe 0.033mm)
Cap #4: slightly larger than 0.038mm
Cap #3: slightly larger than 0.038mm
Cap #2: slightly smaller than 0.051mm
Cap #1: very slightly larger than 0.038mm

Spec is 0.0150-0.034mm for all but #3, which is 0.025-0.044. So, #3 is the only one that's really in spec, with #5 (on the flywheel side) being close to the top end of the range.

Come to find out, Toyota has five different main bearings for the 3SGTE. Clevite (the ones I have) are all size 1. I couldn't check my old bearings for a number because I'm not sure which order I put them in vs how they came out, so I had to look at the block and crank to see.

The block is stamped 32122, in order from crank pulley to flywheel. The crank is stamped 01000. To determine bearing size, you add the numbers together. So, I need bearings sized 3, 3, 1 (center), 2, 2.

The one that I do have in spec is #3, which is 0+1=1...confirming that the Clevite bearings are size 1.

So, I need OEM bearings 2x #3 and 2x #2. The factory service manual is amazingly helpful. :awe:

 

[jlee]

Today, I ordered new OEM Toyota main bearings, rod bearings, and throw out bearing.

 

[JCH13]

:awe:

 

[jlee]

moar toys!

 

[exdeath]

OMG racing grease.

 

[jlee]

Moar.

4800cc of fuel good for ~750whp on gasoline, ~560whp on E85 at stock fuel pressure.

I am shooting for 350-400whp, but headroom is good.

 

[JCH13]

Awwwww yeah.

 

[exdeath]

P9001: insufficient manifold pressure

 

[FuzzyDunlop]

Geeze those are huge injectors. Nearly 3x larger than stock. Nutty.
but wait.... You'll get more hp from gasoline than e85?

 

[JCH13]

Geeze those are huge injectors. Nearly 3x larger than stock. Nutty.
but wait.... You'll get more hp from gasoline than e85?

That whole lower energy density with E85...

... assuming you don't knock so much that the engine explodes when using gasoline. It's a theoretical limit, not a practical limit.

 

[jlee]

That whole lower energy density with E85...

... assuming you don't knock so much that the engine explodes when using gasoline. It's a theoretical limit, not a practical limit.

Yup. I can run much more boost on 100+ octane E85 vs the 91 octane crap we get here in AZ. 15psi vs.....well, E85 is good to 40+psi. Far more than my engine will take.

 

[exdeath]

Geeze those are huge injectors. Nearly 3x larger than stock. Nutty.
but wait.... You'll get more hp from gasoline than e85?

Yup. E85 = less energy per unit mass of fuel. But you get the power back and then some due to different AFRs and timing.

Nitro methane has one if the lowest energy densities of motor fuels, but having 1.7:1 AFR means 37% of you cylinder is fuel instead of only 7% (12.8:1).

1/3 the energy but ~ 5 times the fuel = 1.6 times the power but with 5 times the fuel flow (hence gasoline > E85 given a fixed injector size provided the engine stays together).

Plus other properties like detonation resistance, cooling, etc.

What if you could run a fuel that had half the energy of gasoline but you could run infinite boost on it without detonating?

 

[jlee]

Assembled with Amsoil breakin oil on the valve stems and assembly lube wherever else I thought it should go (hindsight being 20/20, assembly lube would've been good on the valve stems too but oil is fine - recommended by the factory service manual anyway).

If you ever take a Toyota head apart, get this tool! http://www.toyotool.com/ It's worth so much more than they ask!

I lapped the valves and assembled everything today. I may shim the cams before the weekend, then it'll be ready for me to rebuild the distributor and assemble the rest of the head. The last bearings (#3 main and clutch throw out bearing) should be here Friday. The rest of the main/rod bearings are here now, so once #3 comes in I can check clearances on the crank, bolt the crank in, then check clearances on the rods. I could check/file piston rings now too.

I don't believe I am waiting for any more parts or tools...should all be up to me now.

 

[FuzzyDunlop]

your going to have this ready and back in the car in no time.
Break in oil should be fine for the stems. as long as they arent dry. Im excited to see how she looks all put together again.
Are you working on the engine bay at all, to clean it up some?

 

[jlee]

Engine bay....


>.>

<.<

You'll see.

I went home for lunch and assembled the buckets/shims, set the cams in place, and put the caps on. When I get home I'll torque them down and check clearances. Hopefully I'm okay as-is but I may need to swap some shims around. Intake valve #7's bucket is a little tight and is not moving around as easily as I would like. I'm hoping after I work it back and forth a couple of times the valve assembly will settle and all will be well.

 

[jlee]

I slowly rotated the cams a couple of times and the valve bucket that was stiff now moves as it should.

All the intake valves are in spec (0.006" to 0.010") except #5, which is 0.012".
Intake #5 shim is .108". I need to make that 0.01-0.06" taller, so I need a .109-.114" shim. I'll aim for 0.008", so 0.112".

All of the exhaust valves are out of spec (0.011" to 0.015"):
0.016 0.016 0.017 0.017 0.016 0.017 0.016 0.018

Exhaust shims are:
0.106 0.106 0.106 0.105 0.107 0.106 0.107 0.105
I need
0.109 0.109 0.110 0.109 0.110 0.110 0.110 0.110

So, I need 3x 0.109, 5x 0.110, and 1x 0.112.

Toyota sells them sized in millimeters:
3x 2.7686mm
5x 2.794mm
1x 2.8448mm

3x 13753&#8209;74110 3SGTE..SW20, T=2.75
5x 13753&#8209;74130 3SGTE..SW20, T=2.80
1x 13753&#8209;74150 3SGTE..SW20, T=2.85

 

[jlee]

Shims are at the dealer, waiting for pickup.

The main bearings were wrong. They were all the #3 bearing. I brought them back and they ordered the proper ones. The piston rings I have are also incorrect - the CP pistons I have use different rings than the "common" CP 86.5mm ring (and the ones I need are also 40% more expensive).

New rings will cost me $112 plus shipping. I paid $350 for the pistons (used). I can get new Wiseco forged pistons for ~$480. Ordered. /fix

Meh. :-/