The Gen 3.5 swap

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The Gen 3.5 swap

Postby l0ch0w » Sat Apr 09, 2011 12:50 pm

So ive been posting this build on the MR2 forums, but the reality is that its better suited here. Ill post my progress up to this point.

So, im starting my gen 3.5 swap into my alltrac, and 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:
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The Gen II block has a coolant nipple here:
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The Gen4 does not:
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Andrew

1991 Red Alltrac
Frankenstein engine, lots of mods :P
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Re: The Gen 3.5 swap

Postby l0ch0w » Sat Apr 09, 2011 12:51 pm

The Gen II has a different size turbo feed line and the that big hole is drilled and tapped:
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The Gen4:
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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:
Image
The Gen4:
Image
Andrew

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Re: The Gen 3.5 swap

Postby l0ch0w » Sat Apr 09, 2011 12:51 pm

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...

Image
By alochow at 2011-03-10
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By alochow at 2011-03-10
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By alochow at 2011-03-10
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By alochow at 2011-03-10
Andrew

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Re: The Gen 3.5 swap

Postby l0ch0w » Sat Apr 09, 2011 12:52 pm

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
Image
By alochow at 2011-03-11

Notice how much thinner the gen 4 cooler is, also no spacer bracket.
Image
By alochow at 2011-03-11
Last edited by l0ch0w on Sat Apr 09, 2011 1:10 pm, edited 1 time in total.
Andrew

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Re: The Gen 3.5 swap

Postby l0ch0w » Sat Apr 09, 2011 12:54 pm

More pictures, also the modification of the oil pan so I can run ARP main studs.

Image
By alochow at 2011-03-16

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By alochow at 2011-03-16

Image
By alochow at 2011-03-16
Andrew

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Re: The Gen 3.5 swap

Postby l0ch0w » Sat Apr 09, 2011 12:55 pm

Ok so here are the two coolest parts...
Image

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Re: The Gen 3.5 swap

Postby l0ch0w » Sat Apr 09, 2011 1:06 pm

The current status:

Ordered a full engine gasket and seal kit from Lithia. The rotating assembly is going out Thursday to be balanced. The ARP 2000 head studs will be coming in next week, and all new bypass hoses (the ones that arent the HFH and HFHOE) are headed here straight from Japan (im tempted to buy a geiger counter to see if its radioactive :) )
Andrew

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Re: The Gen 3.5 swap

Postby l0ch0w » Sat Apr 09, 2011 7:16 pm

OK, maybe I should explain the whole swap first off...

So 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...

Phase one is to essentially get it running. However, Precautions are being taken so that the motor can handle future upgrades. First is a set of 86.5mm wiseco pistons from ATS racing. They have ceramic coated domes, and an anti friction coating on the skirts. Secondly is a set of Billet Crower Rods. Unless I can sell my RC/CS turbo, For now I will be using that. Eventually I will buying a twin scroll Borg Warner EFR 8374 with a custom manifold made by Marc at EMS powered. But thats about a year off... Anyways, on to the stuff I currently have. 1600cc injectors, AEM UEGO wideband, ARP 2000 head studs from KO racing, All new hoses, seals, and bearings straight from japan/toyota. After I pay for school, im going to buy an aem EMS 4 as my standalone. I used to run an AEM PNP, but I sold it since they have classically had issues.

My first goal after getting it running, is to see what the power capabilities are of the RC/CS turbo (unless someone buys it). It has a larger compressor wheel than the standard ct26, but isnt quite the same size as the 20b. The good thing is that it has the inconel turbine, which means its rebuildable :) Ive never really seen a full build on the RC/CS turbo, so right now its pretty much an academic exercise.
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Re: The Gen 3.5 swap

Postby l0ch0w » Sun Apr 10, 2011 8:20 pm

I guess it must be too nice outside for anyone to care...
Andrew

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Re: The Gen 3.5 swap

Postby CMS-GT4 » Sun Apr 10, 2011 8:21 pm

Its an interesting thread, but forum activity drops a bit from mid day friday to mid day monday. You get used to it.
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Re: The Gen 3.5 swap

Postby l0ch0w » Sun Apr 10, 2011 9:26 pm

im spoiled, im used to the mr2oc forums...
Andrew

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Re: The Gen 3.5 swap

Postby UtahSleeper » Mon Apr 11, 2011 5:51 am

We care :) Just starting to get nice out. I do most of my surfing at work lol.

Nice work so far. I will have to see where this goes.
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Re: The Gen 3.5 swap

Postby l0ch0w » Mon Apr 11, 2011 7:58 pm

im getting a bit antsy, my arp2000 head studs come in today :)
Andrew

1991 Red Alltrac
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Re: The Gen 3.5 swap

Postby Gary ST165 » Mon Apr 11, 2011 8:09 pm

keep posting them pictures 8) / thanks for sharing :smokes:
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Re: The Gen 3.5 swap

Postby l0ch0w » Sat Apr 16, 2011 1:46 pm

Head Studs Came in

Image
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.

Image
By alochow at 2011-04-14

Image
By alochow at 2011-04-14
Andrew

1991 Red Alltrac
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