3S-GTE rebuild.... *Finished!*

[GT4 20]

While I was swanning around Europe, the new pistons were successfully fitted to the revised block (long story )....





... we couldn't get some ACL +1mm pistons so turned to a set of Wisecos from the US...



So, with that part completed, I could now start putting everything back together..



ARP studs fitted along with the new HG...



Oil pick-up and splash pan fitted following a few hours in the acid bath....



New crank oil seal fitted....



Due to different cams, altered CR and different pistons, a test was required to ensure that valves and pistons didn't come into contact with each other so off to the local toy shop for some...



This was then put onto the piston crowns where the valves would likely come into contact...



Once all 4 pistons had been set so they sat half way up the bores, the cylinder head could be fitted and torqued into place....



The top cam cover backing plate and lower belt cover were fitted next to ensure that the cam wheels and bottom pulley were positioned correctly....



.... prior to the cambelt being fitted....



Once everything was properly assembled, the engine was carefully turned over for a few revolutions, taking care to ensure that there was no unwanted resistance.

Then, the belt and head were removed so the doh on the pistons could be inspected. This revealed plenty of clearance between pistons and valves. Obviously a good thing....



With the doh removed, the head could be refitted. This being the current state and the end of play today...



Work prevents me from doing more until Friday morning when the rebuild will continue. Watch this space
Gary

[Adydas]

What was the cost for the pistons? what gains are you to get from them Or are they just cleaned stock ones?

[GT4 20]

what gains are you to get from them Or are they just cleaned stock ones?

As stated above, the are Wiseco pistons, not 'cleaned stock ones' These are forged and allow higher boost to be run.
Gary

[Adydas]

i couldnt be botherd reading hah, i did assume something was not factory about them and they were there for more boosting purposes.

Do you mind, How much were the pistons etc?

[Malcolm]

is that a gen 2 block you're using now?
from this pic:

it looks like you have the same issue with the coolant hole on the headgasket on the exhaust side of #2 cylinder not lining up perfectly with the block.

looks the same as mine (wont post the pic because it's big but):
http://www.fasterthanjesus.net/sw11/gen3hg.jpg

I hadn't decided yet whether this was a problem or not, but I was thinking about slightly slotting the hole on the headgasket to accomodate it.

You already had normal sized ACL pistons didn't you? Did you have to go overbored for some reason?

[Dell'Orto]

Bout time something got done too much gallivanting in Europe, not enough rebuilding!

[GT4 20]

is that a gen 2 block you're using now?

Nope. Gen III.

You already had normal sized ACL pistons didn't you? Did you have to go overbored for some reason?

Yes. Through no fault of mine, one of the bores was damaged when the ACLs were being fitted. Needed to go to 1mm oversized to get rid of the 'scratch' in the cylinder wall. Had the block ultrasonically tested between #2 & #3 cylinders to ensure there was enough material between the 2 before going ahead. Fortunately there is.
Gary

[RomanV]

What do you mean when you say 'revised' block?

Did you bore out your old block by 1mm, or did you get a new block, and bore that out?

Either way, it looks like it is coming along well.

Keep the pics coming!

[GT4 20]

Sorry, didn't explain teh entire story.

Original block was bored out to +0.5mm. ACL pistons were inserted but when one was going in, the bottom oil control ring sneaked out between teh ring compressor and the block unnoticed (not by me I hasten to add ). As a result, the rind was obviously damaged, but the cylinder bore was also deeply scored. We tried a a 10thou (IIRC) overbore but the score mark was still there.
Given the issues between #2 & #3 cylinders on the early Gen III blocks, a +1mm overbore was potentially fraught with problems. So and ultrasound test was performed before going ahead. So the block was bored out to accommodate the new +1mm pistons - hence the term I used. Sorry for any confusion
Gary

[Lanius]

Awesome pictoral timeline man, thanks
Hope there are no more hiccups in the work!

[Akane]

is that a gen 2 block you're using now?

You're not the 1st to ask, I've asked before since the oil filter sits on the top instead of Gen 3's bottom (afaik, not that i've really worked on a Gen 3), but Gary insisted his is a geniune Gen 3 instead of a gen 2.

oh well, if that makes him a believer, go for it Gary! We Support you!

Maybe it's time for me to ditch the Gen 1 engine and get a Gen 2 and slot my JE pistons back in, been sitting around for so long.....

[fivebob]

You're not the 1st to ask, I've asked before since the oil filter sits on the top instead of Gen 3's bottom (afaik, not that i've really worked on a Gen 3), but Gary insisted his is a geniune Gen 3 instead of a gen 2.

My eyesight must be going as all I see is a Gen III oil cooler, no filter.

BTW it's definitely a Gen III block, of course it helps if you know the differences and what to look for before making such statements

[Mr Revhead]

re the revised block, theres a supercession in the early st205 blocks.
so at some point they made a change to them.
same shows for the sw20 blocks.

and no im not talking about the changes from 89-93.

[fivebob]

re the revised block, theres a supercession in the early st205 blocks.
so at some point they made a change to them.
same shows for the sw20 blocks.

and no im not talking about the changes from 89-93.

Is this the changes made in '98 or something else?

[Mr Revhead]

all i can tell is they were between the end of 93 and begining of 98. so somewhere in there they decided something needed changing. after the 1st 98 they all (cant have been many) had the revised block.


id need to do more looking, theres a coupla other part numbers listed to do with the oil pan, and a bolt with washer....

usually in that case (supercession with other numbers listed) those other parts are required when changing from the previous part number to the latter. but not always. unfortunatly i dont have easy acsess to the whole sepercession list.

also a supercession usually relates to a change made after producton. as in a change was needed, so they list the replacement part as the supercedded number.

[RomanV]

Hrmm, perhaps I should make a similar thread when I finally rebuild mine.

A lot of the parts look identical to the gen 3 engine.

Except for the oil cooler, which I think may look a little different.

But that might be a turbo/NA difference anyway?

[Akane]

My eyesight must be going as all I see is a Gen III oil cooler, no filter.

BTW it's definitely a Gen III block, of course it helps if you know the differences and what to look for before making such statements

I'm not claiming that I know the Gen 3 block, just that I've heard the gen 3's oil filter points downwards, and I don't see an oil filter mounting location anywhere, and couldn't think of one unless it goes ontop of the oil cooler just like the Gen 2. I do notice however the bolt that goes ontop of the oil cooler, which explains there could not be oil flow in the way of a Gen 2 does with the hole in the middle.

we could do with a bit less sarcasam too.

[Malcolm]

is that a gen 2 block you're using now?

Nope. Gen III.

That's certainly interesting. That means I will not worry about the mis-match in the water passage and headgasket on mine

You already had normal sized ACL pistons didn't you? Did you have to go overbored for some reason?

Yes. Through no fault of mine, one of the bores was damaged when the ACLs were being fitted. Needed to go to 1mm oversized to get rid of the 'scratch' in the cylinder wall.

So...what happened to the old ACLs?

[Malcolm]

I'm not claiming that I know the Gen 3 block, just that I've heard the gen 3's oil filter points downwards, and I don't see an oil filter mounting location anywhere, and couldn't think of one unless it goes ontop of the oil cooler just like the Gen 2.

Here ya go Kenny, this is where the Gen 3 oil filter sits (this is BBBrad's engine)


It's kind of hard to see because it's a white filter, but its on the sump down the bottom there.

The Gen 3 has a similar oil cooler to the gen 2, only instead of having a bolt which feeds oil through to the filter, it has a banjo-type bolt going through as you can see in the pics

[Dell'Orto]

So...what happened to the old ACLs?

I believe he's waiting for you to purchase them