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1991 AT Engine Disassembly And Reassembly

PostPosted: Tue Apr 05, 2016 3:05 pm
by Il_Barone
Hope to be in the right section.

4 months ago my engine block crancked near the water pump.
Reding this forum i found out that is a common problem of this type of engines, so i found an used Rev2 block and last sunday we started to disasembly the old 3sgte.
Here it is:

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I've already ordered this kit: 86.5 CP Pistons kit, Eagle Rods, Arp Head Studs and the MLS head gasket (standard size)

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In the next days i'll publish updates :)

Any advice is welcome :)

Have a nice day

Daniele

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Mon Sep 19, 2016 3:17 pm
by Il_Barone
Update:



My setup is:

Gen2 head with Gen3 camshafts
Gen2 block with:
- Cometic steel head gasket (thick as the original stock)
- CP pistons (86,5mm diameter)
- Eagle rods
- ACL complete bearing set
- Stainless Steel exhaust system
- Crankshaft and flywheel balanced

I'd like to keep the original ECU. What is your opinion about? :)
I'm not planning any boost level increase.

Now i'm looking for the spark plugs, i think i'll buy 4 NGK BKR6EP8.
I can't find the Denso plugs anywhere.

Here there are some pics of the new engine:



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Any advise is welcome :)

Daniele

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Fri Sep 30, 2016 2:03 pm
by zedxfarin
The is inspiring!! :notworthy:

I Will be following :)

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Fri Sep 30, 2016 8:35 pm
by awdmofo
im actually doing the same thing starting this weekend :D excited to crack this used engine open and see how bad it is compared to my already blown one. How long do you think it will take you do clean everything up and put it back into the car? Are you going to replace the clutch/flywheel while its apart?

viewtopic.php?f=44&t=51613

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Sat Oct 01, 2016 7:34 pm
by ST185l
wow, could put photos cranked, I have never seen any and if it is a common mistake ... you'd better be forewarned

It is a common error in 1/3 and 4 gene?

I could tell what has cost kit pistons reconstruction, etc. I'm in a similar situation and would like to forge better quantify whether or not forge

Bearing set is part of the kit or purchased separately, if so might know your price?

Where he bought all materials / parts, know if you ship to Spain?

What improvement or how much improvement expected from the camshafts 3 gene

A great job, muchisimos encouragement and thanks for sharing with us.
I hope these advances

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Sun Oct 02, 2016 6:16 pm
by GT4times2
IF you're not going to modify the car much, the stock ECU should be Ok. But fuel, cams, turbo upgrades...... :nono:

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Mon Feb 20, 2017 12:02 pm
by Il_Barone
Something is moving, very slowly :)

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Yesterday night we mounted the intake manifold, injectors and the wiring.

Anyway, i noticed for the first time a modify on the turbo, here it is:

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There are two pipes, one on the front (in the picture, where the metal cover is cut) and one on the back of the CT26.

What do you think it is, a custom water-cooling modify?

Ciao! :)

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Wed Mar 01, 2017 10:15 am
by Il_Barone
Is there any moderator who can move this topic to "my project"?

Maybe it's the correct section.

Thank you

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Sat Mar 04, 2017 5:30 pm
by awdmofo
nice!! you lied on my build page, you're way ahead of me in my build :D. Machine shops still has my block and working on the head next week. What flywheel/clutch did you go with? Any reason you don't want a CT-20B turbo or something more fun? with some fuel upgrades and a customer computer you can make that engine fly :shock:

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Thu Mar 09, 2017 3:57 pm
by Il_Barone
It works!

First, we run the engine without the coil to put the oil (Castrol Magnatec) in circulation, then we connected the coil and it turned on at the first try :)

Maybe tomorrow evening we'll do the first ride after a long time, we still mount one driveshaft boot and new tires.

Here there's a picture of the engine complete and one of another friend of ours (in addition to the forklift)

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Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Thu Mar 09, 2017 4:15 pm
by Il_Barone
awdmofo wrote:nice!! you lied on my build page, you're way ahead of me in my build


We started the job one year ago, more or less :D :D

awdmofo wrote:What flywheel/clutch did you go with?


Original clutch. Original flywheel too, but it's balanced.

awdmofo wrote:Any reason you don't want a CT-20B turbo or something more fun? with some fuel upgrades and a customer computer you can make that engine fly :shock:


First reason is money :D

Second and more important reason is that i'm afraid my new block can crack again.
I don't know why the old block cracked, it was a stock engine always and well mantained. It cracked near the water pump.

About that, any possible suggestions are welcome.

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Mon Mar 13, 2017 12:17 pm
by Il_Barone
Bad news guys.
Very bad news.

It leaks coolant from the head gasket. Exactly from the layers of the gasket.

With the engine on, we can see the coolant dripping from that precise point (in the red circle)

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We torqued the head bolts following the BGB instructions.

We have not re-torqued them yet. Maybe it's the reason of that leak?

The head gasket is a Cometic with ARP bolts. Block and head were machine-shaped.

Did the same thing happen to you? Or do you know if it's a possible problem with Cometic gaskets?

I'm very demoralized :(

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Thu Mar 30, 2017 9:47 pm
by outinnowhere3193
arp head bolts require more torque if I remember right. you should follow the arp torque specs.

But none the less it shouldn't of leaked at all. I personally always copper coat my gaskets even though cosmetic says no need to do so.

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Fri Mar 31, 2017 11:48 am
by Il_Barone
We re-torque the head bolts and it doesn't leak anymore!!

We did about 10 km of road test, the engine goes very fast, the Japspeed stainless steel exhaust makes a beautiful sound :D

Next week we'll take the car to the bodyshop for a complete repainting

Pictures coming soon :D

outinnowhere3193 wrote:arp head bolts require more torque if I remember right. you should follow the arp torque specs.

But none the less it shouldn't of leaked at all. I personally always copper coat my gaskets even though cosmetic says no need to do so.


We re-torqued the head (in the ARP box there was no specs about the torque specifications) but we didn't use any gasket sealant.

Re: 1991 AT Engine Disassembly And Reassembly

PostPosted: Fri May 12, 2017 2:35 pm
by Il_Barone
Almost ready

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