Cant believe it's been a year since I've updated this thread, so just posting some updates regarding the car. The goal was to turn this car into the AllTrac I've always wanted, and as you can see that takes time. I had an opportunity to pick up another 165 that was already pretty much what I wanted this car to be, not to mention it was a single owner car with quite a bit of history. With that said, this car has since been passed on to a close friend here on the forum who will continue developing the car; he'll create a build page to consolidate all this. I'm currently working to complete this car, although the build is now a bit more realistic and practical (still 3rd gen).
I've spent the last few months building the motor, head and turbo system as time has allowed. Here's a summary of the progress:
* 3rd gen head was refreshed with new valve seals, Engle springs and held down with ARP head studs
* 3rd gen block was hot tanked, honed, Eagle rods and Arais pistons (86mm) installed with ACL main and rod bearings
* New oil pump, water pump, thermostat, timing belt & tensioner, seals (mains, cams, etc...), all new gaskets (including 3rd gen head gasket)
* Holset HY35 was upgraded from a 54mm comp wheel to a 60mm HX40 wheel (still 9cm turb. hsg)
* Fabbed wastegate adapter to still run oem manifold heatshield
I'm sure there is some other things I'm forgetting, but I'm definately grateful that the car came with a full 3rd gen engine rebuild kit. Just need to put the engine on a cradle and install the flywheel/clutch/tranny and then focus on getting her back in the car. from there it's just re-installing the engine harness (with a slight tuck) and re-tuning the Haltech for E85. Still need to install the fuel rail and injectors (1000cc). Anyway, here are a lot of pics of the progress:
How she currently sits..
Head prepped for re-assembly
I was able to move the shims around (bottom right), in order to keep in the center of the tolerances
Bare block after hot-tank and hone; they actually chased all the bolt holes at no additional cost
Dont you just love squirters
Installed
Crank installed and main torqued
Checking ring-gap after filing the rings; gap set to .020
Ready to install the rings and drop them in the bore
It's a shame these will be hidden by the head
ARP studs installed
Rod caps torqued down. I'm using Permatex Assembly Lube if anyones wondering (very sticky)
Suction tube and windage tray installedAint she purdy?
Upper oil pan installed
Lower oil pan installed
Head back together. I used Redline assembly lube to keep the keepers on the valve stems (worked well)
Cut my finger on the corner of the head and bled all over it.. J/K it the Permatex assembly lube
Cams/gears installed and torqued
Running stock 3rd gen cams for now, but we may pick up some additional HP by playing with them on the dyno.
I have a set of new GSC 268s on the shelf just in case
Turbo is a Holset HY35/40 (9cm hsg). I'm very curious how it will spool and perform mid-range and up top
The owner wanted a stock'ish look, so I'm fabbing the wastgate lacation to keep the OE heatshield
Came out pretty good. It'll be open vent..
Gotta fab up the 3" downpipe and w/g dump tube; almost there
A few things left to install
Re-plenum Manifold (Q45 tb)
Competition Clutch Stg-4 kit w/ Flywheel (steel)
T-Netics intercooler (garrett core)
I've spent the last few months building the motor, head and turbo system as time has allowed. Here's a summary of the progress:
* 3rd gen head was refreshed with new valve seals, Engle springs and held down with ARP head studs
* 3rd gen block was hot tanked, honed, Eagle rods and Arais pistons (86mm) installed with ACL main and rod bearings
* New oil pump, water pump, thermostat, timing belt & tensioner, seals (mains, cams, etc...), all new gaskets (including 3rd gen head gasket)
* Holset HY35 was upgraded from a 54mm comp wheel to a 60mm HX40 wheel (still 9cm turb. hsg)
* Fabbed wastegate adapter to still run oem manifold heatshield
I'm sure there is some other things I'm forgetting, but I'm definately grateful that the car came with a full 3rd gen engine rebuild kit. Just need to put the engine on a cradle and install the flywheel/clutch/tranny and then focus on getting her back in the car. from there it's just re-installing the engine harness (with a slight tuck) and re-tuning the Haltech for E85. Still need to install the fuel rail and injectors (1000cc). Anyway, here are a lot of pics of the progress:
How she currently sits..
Head prepped for re-assembly
I was able to move the shims around (bottom right), in order to keep in the center of the tolerances
Bare block after hot-tank and hone; they actually chased all the bolt holes at no additional cost
Dont you just love squirters
Installed
Crank installed and main torqued
Checking ring-gap after filing the rings; gap set to .020
Ready to install the rings and drop them in the bore
It's a shame these will be hidden by the head
ARP studs installed
Rod caps torqued down. I'm using Permatex Assembly Lube if anyones wondering (very sticky)
Suction tube and windage tray installedAint she purdy?
Upper oil pan installed
Lower oil pan installed
Head back together. I used Redline assembly lube to keep the keepers on the valve stems (worked well)
Cut my finger on the corner of the head and bled all over it.. J/K it the Permatex assembly lube
Cams/gears installed and torqued
Running stock 3rd gen cams for now, but we may pick up some additional HP by playing with them on the dyno.
I have a set of new GSC 268s on the shelf just in case
Turbo is a Holset HY35/40 (9cm hsg). I'm very curious how it will spool and perform mid-range and up top
The owner wanted a stock'ish look, so I'm fabbing the wastgate lacation to keep the OE heatshield
Came out pretty good. It'll be open vent..
Gotta fab up the 3" downpipe and w/g dump tube; almost there
A few things left to install
Re-plenum Manifold (Q45 tb)
Competition Clutch Stg-4 kit w/ Flywheel (steel)
T-Netics intercooler (garrett core)
