Time for an update. Unfortunately it's not a good one!
While I was at the MR2 Wakefield Park Challenge last week, I was experiencing some strange problems that I couldn't figure out. Also, one of the times that I was accelerating up the back straight, I thought I heard the sound of the engine suddenly change slightly (around the peak torque point), but I thought I was imagining it. However, on the drive back to Sydney I became more convinced that the engine wasn't sounding quite right. It didn't sound horrible, just a bit more 'groany' than normal at mid-to-high revs.
Well, as it turns out, some of my main caps have failed/cracked. They're the stock cast items.
This is the first internal failure of the engine in the ~7 years since it was first rebuilt, so it's had a very good innings considering the abuse that I've put it through. The failure still suuuucks because I have less disposable income these days and it's going to be a very expensive fix. I knew it was only a matter of time haha.
The main caps may be very simple items, which are easily accessible with the sump removed, but the worst part of this situation is that the whole engine has to be removed and the block stripped down to properly line/align bore/hone the block and the replacement main caps.
So, to make the most of the labour required, I'm finally going to do a 5S-GTE conversion. I'll probably keep the same turbo and see how much the response improves with an extra 10% engine capacity. I need to track down a 5S block and crank ASAP to get the ball rolling. I could buy a brand new 5S crank from Toyota, but I'll only do that if I can't find a good used one.
Before anyone brings it up, no I'm not going to do a V6 swap or K24 swap. They're both fantastic options, but I've been very happy with the 3S-GTE and I'll be even happier with a 5S-GTE. Cost is also a major factor.