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Hot!Kojab's 1993 GT Hardtop Project

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kojab
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2018/06/16 11:22:28 (permalink)
5 (3)

Kojab's 1993 GT Hardtop Project

I am retired now so finally can get back, or start my long awaited project.
 
It all started a few years ago when I picked up this.  Some of you will remember seeing it on this forum.

 
You can read more about the specs of this engine in this post.
https://www.mr2australia.com/mr2play/tm.aspx?m=95558#95915
 
The next thing I needed was a SW20 shell to put it in.  This took me several years to find and I finally bought this. Little did I know at the time, that this shell used to have the very same engine installed as you see above.  Turned out the shell and engine came originally from the same owner.
https://www.mr2australia.com/mr2play/tm.aspx?m=132115
 
 
A year and half later I can now really enjoy putting the two together and look forward to tuning it.
post edited by kojab - 2018/06/16 11:55:10

Attached Image(s)


92' SW20 3SGTE   GEN2 GT Hardtop
87' AW11 3SGTE   Now Delco EFI ecu & 21 psi boost
71' KE25 3TGTE    Delco EFI ecu. Unopened std engine 24 psi boost
78' KE55 L67        Delco EFI ecu
#1


13 Replies Related Threads

    kojab
    MR2 Master
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/18 12:01:14 (permalink)
    +2 (2)
     
     
    With the engine now off the stand and sitting on my heavy duty caster engine trolley I torqued up the new Xtreme FTY001CL billet lightweight chrome molly steel flywheel.  The attached steel strap is my way of stopping the flywheel from turning during torque up.
     

    Fitting transmission made easy using chain block. Just push engine that's sitting on the trolley towards the transmission.  One man job.
     

    Made up two eye bolt flanges to lift SW20 body with my gantry and two chain blocks.
     
    Next thing is to remove rear cross member off the rolling shell to allow the engine to be installed.
     
     

    Attached Image(s)


    92' SW20 3SGTE   GEN2 GT Hardtop
    87' AW11 3SGTE   Now Delco EFI ecu & 21 psi boost
    71' KE25 3TGTE    Delco EFI ecu. Unopened std engine 24 psi boost
    78' KE55 L67        Delco EFI ecu
    #2
    Falcon
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/20 08:25:15 (permalink)
    +1 (1)
    Very very nice. Congratulations. Strap on flywheel is perfect to prevent crank being rotated backwards.
    A couple of observations. Can the turbo oil feed line be moved toward the compressor a bit to be further away from the radiated heat coming off the turbine housing. On the same problem. Are you installing heat shrouds over the exhaust manifold and turbine housing to protect the compressor and it's hot pipe?
    Why are the studs so long that hold the turbo to the manifold? They are b^~~~~ds to get at without extra long studs to avoid as well.
    What are you using for oil cooling ? I assume that is a Gen 2 engine. Their coolant pipes to the original oil cooler leave a bit to be desired. Enjoy your retirement. Cheers.
    #3

    kojab
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/20 10:28:06 (permalink)
    +1 (1)
    Appreciate your observations.
     
    Makes sense to try and move the turbo oil feed line away from the turbine housing.  Yes I am going to have to get some form of heat shielding happening.  I have a border A2A intercooler to go on top of this engine as well to think about so the shielding and its configuration will be complex.
     
    The studs that hold the turbo to the manifold are the ones the PO fitted. He went a bit overboard with high tensile bolts and there lengths in several locations.
     
    Yes engine is a Gen 2 and having never dealt with so much stainless steel braded hoses before assumed that the oil cooler pipes would have been of the correct type of hose.  How did you pick they were coolant pipes? 
    I am very pleased you noticed this.  I just assumed the PO new what he was using.

    92' SW20 3SGTE   GEN2 GT Hardtop
    87' AW11 3SGTE   Now Delco EFI ecu & 21 psi boost
    71' KE25 3TGTE    Delco EFI ecu. Unopened std engine 24 psi boost
    78' KE55 L67        Delco EFI ecu
    #4
    5SGTE
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/20 13:58:10 (permalink)
    0
    I think dougs looking for the oem oil to water cooler, I think I can just spy it there.
    #5
    5SGTE
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/20 14:00:03 (permalink)
    0
    I am curious where the coolant returning the the thermostat housing is from though. I'm assuming turbo.
    #6
    Falcon
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/21 05:11:40 (permalink)
    0
    No Kris. I'm not looking for the OEM oil cooler.
    #7
    Falcon
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/21 06:39:00 (permalink)
    0
    KOJAB. My question was. Are you going to use the original oil to water cooler and if yes does it still have it's original water supply pipes ?? Gen2 draws water from back of block on flywheel end via a third steel pipe attached to the heater return pipe and the bypass pipe. It flows through HFH to the oil cooler and then through HFHOE to suction side of water pump. That is if I remember correctly!! That steel pipe is often in very poor condition with rust and can't flow properly which will limit the cooler's ability. There is also a nasty little 90 degree bolted joint from HFH to the entry of the cooler. This is also often in bad condition.  If all this has been replaced with flexible hose it might be an idea to check how it is attached to the cooler, water pump and back of block. And just make sure it does form a circuit.
    You are welcome to give me a phone call to have a yarn.
    Came across a swapped in BEAMS engine that had water hoses all arse about face to the extent that it was boiling it's guts out continuously. No circuit to open the thermostat!!!  Unbelievable.  Rooted it.
    #8
    stuka
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/21 12:56:13 (permalink)
    +1 (1)
    Funny how things can sometimes get misinterpreted/misunderstood on the forums!
     
    Richard - the braided oil lines from the stock oil filter location (and oil cooler) to the relocation oil filter kit look like they are good quality and they wouldnt be coolant type pipes so all good. They look like they are orientated nicely away from that hot dump pipe. Doug's comment was a general comment about coolant lines, not your oil lines. The steel coolant pipes that Doug referred to look brand new, or else they were painted. But yes, check the rubber hoses to/from the oil cooler. They should be new and as they have really tight radius make sure they are not pinched or twisted after being installed.
     
    On the engine photo, whats is the black AN type elbow that on the photo is halfway between the stock oil filter location and the relocation kit?
     
     
    #9
    kojab
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/21 20:24:24 (permalink)
    0
    First thanks to all that have commented with their observations and as stuka has said how things can sometimes get misinterpreted/misunderstood.  Its only after reading something many times that you realise what it was they were trying to explain. Fortunately for me I was able to speak with Falcon on the phone and we managed to get through a lot of my questions.  His knowledge like many on this forum is a real welcome to new comers to the MR2 engine like myself.
     
    Stuka:  The black AN type elbow that is on the photo halfway between the stock oil filter location and the relocation kit is a coolant connection under the thermostat housing which runs to the back of the turbo.
    It can be seen much clearer in this link 10 photos down.
    https://www.mr2australia.com/mr2play/tm.aspx?m=95558#95915
     
     
     
     
     

    92' SW20 3SGTE   GEN2 GT Hardtop
    87' AW11 3SGTE   Now Delco EFI ecu & 21 psi boost
    71' KE25 3TGTE    Delco EFI ecu. Unopened std engine 24 psi boost
    78' KE55 L67        Delco EFI ecu
    #10
    Mrskylighter
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/21 21:06:24 (permalink)
    0
    Here is a custom fabricated exhaust manifold heat shield that might work for you. Save you making one or using a stock gen 2 one. Would just need to coat it in your preferred finish.
     
    https://www.tcsmotorsports.com/products/tcs-heat-shield
     
     

    1989 AW11 Gen3 3sgte
    #11
    kojab
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/22 20:43:28 (permalink)
    0
    Nick: Thanks for the  "TCS Gen2 3SGTE Heat Shield link"
     
     
    Removing the rear cross member from my rolling shell was very difficult.  The four bolts had frozen solid. Could not budge them using my 1/2"drive with the longest bar.  Sprayed them as best I could with WD40 and let them soak but had my doubts that I got much penetrating fluid where it needed to be. Tried again an hour later and still no luck. I came to the conclusion that the original engine might have been disassembled in the shell probably removing the cylinder head and just about anything else to enable the block to be lifted out the top of the engine bay.
     
    There was no way I would attempt putting my new engine and gearbox in from the top. Probably impossible with the gearbox attached so back to getting these four cross member bolts free.  Extended my socket bar to double the length and with all my strength finally got them loose and out.
    I was very relieved to find the threads on these four bolts where still in good condition. A good wire brushing to remove surface rust and a wash in kero brought them up good.  Will be using silver goop anti-seize on these four bolts when they go back in.
     
     
    Engine ready to go in.
     
     
     
    I gave it a lot thought about how I was going to lift the SW20 shell without damaging the body and decided to pull it up with two chain blocks connected to the left and right engine mounts.  I had the two long bolts that normally go through the engine mounts available but hooking a chain block hook under one of these bolts would have the tendency to possibly bend the bolt and then distort the engine mount itself on the shell. To overcome this from happening I made up some solid round 1 inch dia spacers the width of the factory engine mounts, a hole through the middle to except the long bolts. Fit the original nut to the long engine mount bolt and tighten up with the new spacer in place and now we have very little chance of bending anything.
     
     
     
    This engine balancer made it very easy to keep the engine/trans at the right angle for relocation back on its mounts.
    The two spacers I used to reinforce the engine mounts while lifting the SW20 shell high enough to get the engine/trans in place for installation.
     

     
     
    Lifting SW20 shell.
    post edited by kojab - 2018/06/23 20:45:43

    Attached Image(s)


    92' SW20 3SGTE   GEN2 GT Hardtop
    87' AW11 3SGTE   Now Delco EFI ecu & 21 psi boost
    71' KE25 3TGTE    Delco EFI ecu. Unopened std engine 24 psi boost
    78' KE55 L67        Delco EFI ecu
    #12
    Lumix
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/23 08:35:47 (permalink)
    0
    Thank you for sharing the build. I looking forward to seeing the car develop over the coming months.
    #13
    stuka
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    Re: Kojab's 1993 GT Hardtop Project 2018/06/23 15:25:56 (permalink)
    0
    Good work Richard, looks like you are making good progress. I have done this same job a couple of times on my own and its all doable. I always seem to have trouble with the driver side engine mount, very fiddly but all works out eventually. 
     
    Thats interesting approach with the hose from the thermostat housing to the turbo, havent seen that done before.
    #14
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