Deco
MR2 Deity
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Re: Bumblebee (another NA -> turbo conversion)
2015/08/09 14:18:06
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Reddtarga
"The tensioner had let loose like I thought. But there was a lot more than met the eye. Turns out that the correct tensioner bearing assembly was not put back on the engine when rebuilt. It was -0.5mm out compared to stock and with an incorrect washer behind it meant that it was out another -0.5mm. Those coupled with the bearing itself having 1mm of movement in it bringing the total to 2mm out. It now makes sense why the belt kept walking and wearing as a result."
I just remembered this post on MR2OC that might be of interest:
http://www.mr2oc.com/showthread.php?t=470147&highlight=tensioner
"Yeah, learned the hard way to ALWAYS check the machine shops work." That's definitely a good thread with some good advice in it haha.
1994 GT with 96 3SGTE (217rwkw)
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Deco
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Re: Bumblebee (another NA -> turbo conversion)
2015/09/10 12:39:50
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Just a small update. So I made a mistake and a not so cheap one of that with the manifold adapter due to not doing enough research. Apparently Toyota moved the turbo over a 1/4" on the gen 3 engines which is enough for turbos to foul on the slave cylinder lines when using this adapter. The other issue was that the wastegate flange was on the side rather than sticking out the front of the adapter, this was a minor issue however that would be easy to fix through a bit of fabrication.  Any who I decided to bite the bullet and order the very pricey but nice ATS adapter. With having it arrived early this week I can begin to make some progress and get the turbo/lines fitted up now. 
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Deco
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Re: Bumblebee (another NA -> turbo conversion)
2015/10/07 12:42:17
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Not a lot of progress has happened unfortunately. I have the turbo etc mostly mocked up but have been waiting for fittings to bridge the coolant lines to the stock ones.
Things left to do before the engine goes back in:
- Finish mocking up coolant lines
- Heat wrap return coolant line
- Reduce the length of the oil feed line
- Mock up oil return line.
- Paint ATS adapter.
- Reinstall turbo etc with all gaskets and washers.
- Install ACT clutch
- Install new timing belt
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MR2QIK
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Re: Bumblebee (another NA -> turbo conversion)
2015/10/08 18:40:30
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As for the motor, you may be able to go to fair trading & at least ask about your options without paying. Uphill battle, but worth a try so at least you know you did nothing.
MR2QIK - "The Little Car That Could"  320rwkw @ 19psi (pump fuel, no giggle gas) 11.96 @ 116mph (with 228rwkw)
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Deco
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Re: Bumblebee (another NA -> turbo conversion)
2015/10/22 08:36:12
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Still not much progress has been made other than having to fabricate a new oil return fitting after I broke the supplied one. Currently am waiting on the clutch which is taking a while as ACT sent the wrong one. So I'm looking at a 2-3 week wait at the moment. But here's a shot of the turbo mocked up on the engine. 
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Deco
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Re: Bumblebee (another NA -> turbo conversion)
2015/11/30 14:24:40
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The clutch arrived and is now finally bolted up on the engine. 
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Deco
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Re: Bumblebee (another NA -> turbo conversion)
2016/01/13 22:35:28
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Long time between updates but the engine is back in the engine bay and runs. Tell you what, the clutch is one mean mother.... It bites incredibly hard! Traffic lights will not be fun haha. I put the car on the trailer this morning and delivered it to the exhaust shop. So not long now till I get to drive it properly. Then in February I plan to install the 850cc injectors along with this baby.  More fun to come; which I hope will involve some track time this year.
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robk
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Re: Bumblebee (another NA -> turbo conversion)
2016/01/13 23:44:41
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Jaemus
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Re: Bumblebee (another NA -> turbo conversion)
2016/01/16 18:22:15
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Nice work dude :) I've missed seeing the yellow 2 at the Sydney meets
Builder / Former owner of: Australia's first V6 converted SW20Current ride: '92 JDM GT turbo hardtop
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MCT_MR2
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Re: Bumblebee (another NA -> turbo conversion)
2016/01/17 11:42:14
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☄ Helpfulby Deco 2016/01/17 21:34:40
Looking good deco.
Just a quick one, i know its not as tilted as it looks in the photo, but are you leaving the turbo core on the angle you have it in your photo with the lines mocked up??
As a rule of thumb, the core should be now more than 30 degrees off upright to ensure oil flows in, lubricates and drains out of the turbo core properly. It looks a bit too rotated in the photo, meaning the bearings (or bushings) might not get lubricated properly, and with the drain on that angle, you will have pools of oil build up in the core, which can give you a smokey turbo pretty quickly.
'88 MR2 4AGTE W/ EFR6258 224.6KW @ 20PSI more to come......
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Deco
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Re: Bumblebee (another NA -> turbo conversion)
2016/01/17 21:34:29
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MCT_MR2
Looking good deco.
Just a quick one, i know its not as tilted as it looks in the photo, but are you leaving the turbo core on the angle you have it in your photo with the lines mocked up??
As a rule of thumb, the core should be now more than 30 degrees off upright to ensure oil flows in, lubricates and drains out of the turbo core properly. It looks a bit too rotated in the photo, meaning the bearings (or bushings) might not get lubricated properly, and with the drain on that angle, you will have pools of oil build up in the core, which can give you a smokey turbo pretty quickly.
Thanks for this bit of information. It's incredibly valuable! The final position is more or less the same. I did pay attention to its position as I wanted the flow of oil to be as streamline as possible. However this was the best I could get as the core/intake side rotate together unless I'm missing something? To get it anymore upright the exit of the intake side would be pointing into the engine and not upwards for the intercooler piping.
1994 GT with 96 3SGTE (217rwkw)
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MCT_MR2
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Re: Bumblebee (another NA -> turbo conversion)
2016/01/17 21:41:37
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The compressor covers will always be able to rotate, some easier than others. Garretts have plates and bolts, but from the photos i have seen of your turbo, it most likely has a giant circlip in the back of it. They are a major pain in the ass. Unless you have a giant set of circlip pliers (sometimes it can be done with long needlenose pliers), you free up the circlip and GENTLY tap the housing round. Hit it too hard and you will damage it. If you remove the circlip you may have a hell of a time getting it back on. People that build automatic transmissions, and turbo shops have the tools to do it, yoy could always approach someone local to help you out.
'88 MR2 4AGTE W/ EFR6258 224.6KW @ 20PSI more to come......
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Deco
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Re: Bumblebee (another NA -> turbo conversion)
2016/01/18 10:21:47
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Ah yes I do remember seeing a giant circlip on rear of it. I guess I'll give it to the workshop to do it as I dont think the circlip pliers I have are anywhere near the size to do the job. Thanks again for alerting me to this fact!
1994 GT with 96 3SGTE (217rwkw)
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Deco
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Re: Bumblebee (another NA -> turbo conversion)
2016/01/21 17:18:37
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I picked the car up from the exhaust shop last night and after an embarrassing drive home due to the new clutch. I've found that the turbo isn't boosting and I can only hear a very slight almost not there spool sound. The engine has no power, bad enough that I had to pull into the truck lane going up hills as It struggled to power up hills. Not quite sure if this is due to the absence of boost or if the engine is running rich or both.
Im a little bit worried that something is very wrong. But I will be checking the MBC as I turned it down a bit to be safe as I had the CT20b up at 18psi and I could of turned it down too much. I will also look for boost leaks around the intercooler and the wastegate just in case. I've tried doing some reasearch on the TD06 and what their characteristics are running low pressure to try get an idea if it could just be a not enough pressure situation but unfortunately there isnt much info out there about that.
Oh well, back to the garage......
1994 GT with 96 3SGTE (217rwkw)
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Jaemus
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Re: Bumblebee (another NA -> turbo conversion)
2016/02/01 16:57:48
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Oh lame. Did you already check it wasn't something simple like a blown intercooler hose?
Builder / Former owner of: Australia's first V6 converted SW20Current ride: '92 JDM GT turbo hardtop
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