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  1. #1
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Default The Gen 3.5 Swap

    Hey guys, I have to apologize for not getting the details of this build up on celicatech. I have been working on this build for about the last 5 months now, and while I have posted to other sites. I really should have also been putting it up here... Enjoy

    I have a red 1991 alltrac that Ive had for about 4 years now. Ive broken two motors, mostly due to lack of experience, and patience. After spinning a bunch of bearings, lots of reading, and learning how to properly build and engine. I have decided to properly build a motor without cutting any corners. Which as most of you know means $$$

    My initial setup will start with the gen IV bottom end. For those of you who are unfamiliar with the 4th gen block, It has a reinforced water pump area, and a better alloy composition. The general consensus with the 3sgte community is that the gen 2 block is good to about 800whp. After that its a huge gamble on whether it cracks at the waterpump or between the no.2 and no.3 cylinder. Im hoping in the future that I can break this barrier, but that is several years off...

    My final goals are to get 500awhp on e85. The rest of the details can be found later on in the build
    Last edited by l0ch0w; 09-08-2011 at 08:10 AM.

  2. #2
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    First I thought I would share with all of you some of the specific differences between the gen 4 and gen 2 block. Next week the gen 4 block will be going to the machine shop to get a makeover and some new holes

    The two blocks side by side gen II on the right gen 4 on the left:

    By alochow at 2011-02-14


    The Gen II block has a coolant nipple here:

    By alochow at 2011-02-14
    The Gen4 does not:

    By alochow at 2011-02-14

  3. #3
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    The Gen II has a different size turbo feed line and the that big hole is drilled and tapped:

    By alochow at 2011-02-14
    The Gen4:

    By alochow at 2011-02-14


    The oil cooler location is significantly different, these next two pictures show quite a few differences. The oil cooler mounting holes are only on the genII block. If you look to the right of the oil cooler location, you will notice that there is a coolant nipple on the gen 4 block, and the genII doesnt... Also if you look really really closely you will see that the gen 4 block has threads the whole way down the center hole of the oil cooler location. but the genII block is bored smooth in the hole.
    The GenII:

    By alochow at 2011-02-14
    The Gen4:

    By alochow at 2011-02-14

  4. #4
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    OK so here is the Gen IV block freshly modified to accept the Gen III oil cooler as well as my 86.5mm wisecos, o and i put fresh coat of paint on it!!!

    My next step is to balance the rotating assembly. Ive decided on going back to a stock flywheel as my previous lightened flywheel made driveability a pain in the butt (remember, my car is way heavier than most of you MR2 guys')

    Anyways, enjoy the clean pretty parts...


    By alochow at 2011-03-10

    By alochow at 2011-03-10

    By alochow at 2011-03-10

    By alochow at 2011-03-10

  5. #5
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Here are some pictures that will better explain why I switched to a gen3 oil cooler. Anyways, these pictures say alot...

    Gen4 on the left, Gen3 plus spacer bracket on the right

    By alochow at 2011-03-11

    Notice how much thinner the gen 4 cooler is, also no spacer bracket.

    By alochow at 2011-03-11

  6. #6
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    More pictures, also the modification of the oil pan so I can run ARP main studs.


    By alochow at 2011-03-16


    By alochow at 2011-03-16


    By alochow at 2011-03-16

  7. #7
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Ok so here are the two coolest parts...


    Uploaded with ImageShack.us


    Uploaded with ImageShack.us

  8. #8
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Head Studs Came in


    By alochow at 2011-04-11

    All the Seals came in from Lithia. I was bored so I sealed up the water pump, oil cooler and the hardlines.


    By alochow at 2011-04-14


    By alochow at 2011-04-14

  9. #9
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    For all of you guys who are wondering about crankshaft and rotating mass balancing. Its not all about just making sure that each component is the same weight. For example, your rods have an odd center of mass, which means that even though they may have the same weight, its possible they have different centers of mass. Proper balancing puts the rods on a jig that can measure the heavy end, and the light end separately. Then each of the pistons are balanced by making sure they are the same weight. Usually if you purchase aftermarket pistons, then they come prebalanced.

    Then after precisely balancing the components, and recording their masses and including the masses of all of the small parts too like wrist pins, rings, and rod bearings. A bob-weight is built and installed on the crankshaft. For a complete balance, the whole rotating assembly is assembled. With the bob weights taking place for the rods, rod bearings, wrist pin, c clips, piston, and rings. The whole assembly usually includes the flywheel and bolts, and the crank pulley.

    Some of you at this point are probably wondering, why balance the whole rotating assy if most modern 4 cyl motors are internally balanced? well... frankly its my anal retentiveness I dont like the idea of my flywheel or crank pulley potentially throwing the rest of my system out of whack. Especially since all of my parts arent from the same motor. My flywheel was a freebie , and my crank pulley was bought off another member. As was my crankshaft...

    For those of you looking to balance your crank, ask around and see if anybody locally has an electronic balancer. These things are like finding someone with a mandrel tubing bender... they arent that common and they cost several hundred thousand million billion dollars or something.

  10. #10
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    OK here are some more cool pictures

    My intercooler arrived (after waiting 2 months for shipping)
    The sticker on top has since come off, and it will be headed to get stripped and powdercoated within the next week or two

    By alochow at 2011-04-29

    Painted up the Heat shield with Silicone Heat Paint

    By alochow at 2011-04-29

    I had to drill a hole here, because the Beams Oil pan doesnt have a turbo drain, but the casting in the pan has the spot here to be machined. Im thinking about just tapping the hole and installing an an fitting.

    By alochow at 2011-04-29

  11. #11
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Ok so J's Garage in Japan just blew my mind... They shipped me a package on wednesday... Here it is today... The physics involved is a bit mind boggling, I was expecting them some time next week... Those crazy Japanese must have invented teleportation or something...

    All the "other" turbo and bypass lines and a water inlet. Brand spanking new...


    By alochow at 2011-04-29

  12. #12
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    I'm gonna take my block to josh next Wednesday and hes going to tig on a larger fitting. The pictures will sort of explain things...

    First I cut the end off of a set of gen 4 hardlines that were both damaged, and unusable by me. The end outlet just so happens to be the same OD as the gen 3 HFHOE outlet! This would be great for those potentially doing the gen 3 oil cooling system on their gen 4 blocks since you cant really use the gen 4 hardlines anyways with this setup. That and gen 3 parts like HFHOE and HFH are much easier to source.

    Picture:
    By alochow at 2011-05-04

    Josh will then be welding it over the old outlet. I dont really foresee any problems doing this... its just sort of a pain.

    Here is a mock-up:

    By alochow at 2011-05-04

    For those of you wondering why in the heck is he going through this much pain to make a gen 4 block work. Its primarily because I like the strength of the gen 4 block and oil pan, but i prefer the availability of parts, and the a2w intercooler in the gen 3. I also like the stock crank angle sensor available with the gen 4. I think its hokey looking if I can see a toothed gear on the outside of your motor.





    I secretly want to learn how to cast aluminum just like Mandalay...

  13. #13
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Moar OEM parts!!!


    By alochow at 2011-06-06

  14. #14
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    My solution for keeping the block clean Its a bit hard to see cuz of the picture, but I saran wrapped the whole thing it works great, it keeps everything out of it. For safe measure though I also usually cover it with a trash bag...


    By alochow at 2011-06-06

  15. #15
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Some tool tips

    I really hate these kind of ring compressors... they are a pain in the ass, and 90% of the time one of the f'ing rings pop out between the block and the tool and you have to start all over again...


    By alochow at 2011-06-06

    So thats why I got one of these... It rocked my world, its sad that ill probably only use it this one time... They are totally worth it IMO.


    By alochow at 2011-06-06

    So here is a piston ring filer... If anyone wants me to show how its done, ill be more than happy... It sux and In my case all of my bottom rings were perfect, but all of my top rings needed to have approximately .004in of material removed from each of them. It too will also be for sale since Im pretty sure Itll be a really long time before I gap another set of rings. For 86.5mm wisecos the calculations for the ring gap came out to be something like .019in for the bottom ring, and .017in for the top... I rounded to .020 for the bottom, and then .018 on the top. Mostly because I couldnt find a feeler gauge that had odd numbered increments.


    By alochow at 2011-06-06

  16. #16
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    So I also bought some of the tefzel 22 gauge wire that MANDALAY had recommended. I must say, it comes in alot of different colors


    By alochow at 2011-06-06

    I know i didnt get enough wire, and im sort of dreading rebuilding my harness. The Body harness wiring will remain untouched, and will simply be getting a new covering. But all of the ECU wiring will be getting replaced with the tefzel, and then spliced into the proEFI's short flying lead harness... The VR crank sensor will also be getting its own dedicated shielded wire...


    By alochow at 2011-06-06

  17. #17
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    I got one of these too, If you know where to get them they are super cheap


    By alochow at 2011-06-06

  18. #18
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Here is my clutch. I am going to reuse my old one. Its only got like 3k miles on it, and I never really raced it. Its an ACT extreme pressure plate with the sprung 6 puck clutch. I think its rated to something like 500 ft/lbs...


    By alochow at 2011-06-06

    Some more build-up porn

    A last view of the pistons
    And just in case you were wondering, the little arrow is important, lots of people screw up the direction of the HG, and it causes big problems.

    By alochow at 2011-06-09

    Head is on and torqued down:

    By alochow at 2011-06-09

  19. #19
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Cams and HFH installed

    By alochow at 2011-06-09

    Put to bed for a week or so, cuz my powdercoated stuff got delayed a bit:

    By alochow at 2011-06-09

  20. #20
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    So since the engine itself is waiting on stuff to get done at the powder coaters, i figured id tackle something ive sort of been dreading... rebuilding my wiring harness. I have bough a significant amount of the wiring I need to do the job. But tonight I decided on building up the jig for actually putting it all together.

    The goal is to retain the majority of the body harness wiring (The stuff that doesnt plug back into the ECU)

    The stuff that does plug into the ECU, will be getting all new wiring, plus there are a few things that will be getting added to the system like a wideband UEGO, and COPs. A large amount of things will be getting gutted, like the EGR, AFM and TVIS wiring. And a large amount of things that will be getting reassigned new jobs like the Turbo Pressure sensor wiring area will be the new MAP sensor, and the CSI area will be the new IAT sensor.

    Heres the progress so far (red is stuff thats getting nix'd) I attempted to use a spray can and stencil to outline some of the stuff... but the sharpie still proved to be better... w/e its not meant to be pretty, and will only be used for the harness rebuild...


    By alochow at 2011-06-09


    By alochow at 2011-06-09

  21. #21
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    More pics

    By alochow at 2011-06-09


    By alochow at 2011-06-09

  22. #22
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Heres the pretty parts...


    By alochow at 2011-06-13


    By alochow at 2011-06-13


    By alochow at 2011-06-13


    By alochow at 2011-06-13


    By alochow at 2011-06-13


    By alochow at 2011-06-13

  23. #23
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    here be some porn


    By alochow at 2011-06-22


    By alochow at 2011-06-22

  24. #24
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    Well it took me long enough, but here are some new pictures and an update of whats going on!

    My USSR ghetto-type milspec connectors arrived, they are just what I was looking for!

    By alochow at 2011-07-07

    I got more cable, and I also got 100 feet of shielded coax for the stuff that needs shielding!

    By alochow at 2011-07-07

    I bought some parts for my custom DP that Josh (MR2Josh) will eventually be fabbing up for me

    By alochow at 2011-07-07

  25. #25
    呉音^ nerdy asian kid 唐音 l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w is a splendid one to behold l0ch0w's Avatar
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    I also got an aeromotive 340lph fuel pump!

    By alochow at 2011-07-07

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