GDII's 1990 G-Limited
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This section of the forum is a great resource if you're looking for ideas, and it's a cool way of obtaining technical information that may otherwise not have been posted. (Members can use the Search functionality at top right of the forum to speed up finding things) Please respect others' contributions and don't diss anyone - keep comments helpful, factual, positive and polite. One thread per vehicle or owner please - don't start lots of threads about just one car. And if you need assistance with your car and want to host a spanner day, please use the appropriate section of the forum: http://mr2.org.nz/phpbb3/viewforum.php?f=35 Thank you.
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Re: GDII's 1990 G-Limited
That is epic mate, awesome work
2017 Toyota Aqua G's
Daily Drive: 2005 Honda CR-V Sport (Auto) - SOLD
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Looking Forward To: Supercharged MR2
Daily Drive: 2005 Honda CR-V Sport (Auto) - SOLD
When the Wife Allows: 2020 TRD RAV4 Limited Hybrid
If the Weather is Nice: 2000 GDBSTiV7 Subaru
Looking Forward To: Supercharged MR2
- GDII
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Re: GDII's 1990 G-Limited
Part 3 of 3! Again, huge thanks to my brother for doing this work for me!
Now that the manifold has gone through thousands of heat cycles the stresses in the casting are gone and machining it flat plus adding in the new tab and fixing point will mean it should not warp again.
1. Setting up the old gasket onto the flange to locate the new hole to match.
2. Drilling the new hole. This one is oversized like the majority of them. Only 2 holes on cylinder 3 and 1 hole between cylinder 1 and 2 are smaller to help locate the manifold better. The rest are larger so there is no binding when placing it on the head.
3. Scribing the face to reshape it to look like the ST246 GEN5 3SGTE cast manifold.
4. Probing the drilled hole to locate it so the machine can mill the flange face level as per the OEM fixing points.
5 and 6. New nut contact face milled to match.
7. All reshaped. Looks like a bought one!! You'd never know this tab was even added. Very excited to get this back.
Now that the manifold has gone through thousands of heat cycles the stresses in the casting are gone and machining it flat plus adding in the new tab and fixing point will mean it should not warp again.
1. Setting up the old gasket onto the flange to locate the new hole to match.
2. Drilling the new hole. This one is oversized like the majority of them. Only 2 holes on cylinder 3 and 1 hole between cylinder 1 and 2 are smaller to help locate the manifold better. The rest are larger so there is no binding when placing it on the head.
3. Scribing the face to reshape it to look like the ST246 GEN5 3SGTE cast manifold.
4. Probing the drilled hole to locate it so the machine can mill the flange face level as per the OEM fixing points.
5 and 6. New nut contact face milled to match.
7. All reshaped. Looks like a bought one!! You'd never know this tab was even added. Very excited to get this back.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
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- GDII
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Re: GDII's 1990 G-Limited
While doing the majority of the engine tear down I managed to stuff the head of the exhaust cam gear bolt. So the socket would just slip off it.
A few days ago I tried 3 methods of bolt removal. First I drilled a hole in it to use an easy out. Mine are cheap so mostly just deform. That failed. Then I thought I'd cut a slot in the head to knock it loose with a big screw driver and hammer. That also failed. Then I thought, why not cut the head size down to the next size, a 13mm. This worked after cutting it down and hammering on a 6 point 13mm socket.
This finally allowed me to move forward with some more removal of parts such as the cam shaft seals and the backing plate. More to come on those.
A few days ago I tried 3 methods of bolt removal. First I drilled a hole in it to use an easy out. Mine are cheap so mostly just deform. That failed. Then I thought I'd cut a slot in the head to knock it loose with a big screw driver and hammer. That also failed. Then I thought, why not cut the head size down to the next size, a 13mm. This worked after cutting it down and hammering on a 6 point 13mm socket.
This finally allowed me to move forward with some more removal of parts such as the cam shaft seals and the backing plate. More to come on those.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
- GDII
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Re: GDII's 1990 G-Limited
With the mangled bolt off the exhaust cam gear I was able to inspect the condition of the cam seals. The intake cam seal was still good and not leaking but the exhaust cam seal was a bit worse. It has some odd damage to the face and doesn't appear to be seated correctly. These will be replaced anyway.
Further investigation reveals there is some old seal material still on the head so it never seated properly because of that.
This shows the seal and the oil bit
It's sitting at 3-6 o'clock.
Further investigation reveals there is some old seal material still on the head so it never seated properly because of that.
This shows the seal and the oil bit
It's sitting at 3-6 o'clock.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
- GDII
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Re: GDII's 1990 G-Limited
Removing the cam belt cover backing plate. It's held on by 4x M6 bolts (10mm head). This provides fixing points for the plastic cam belt cover.
Then it needed a good clean. Still a bit dirty in hard to reach places but I'll give it another good go later on.
Then it needed a good clean. Still a bit dirty in hard to reach places but I'll give it another good go later on.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
- GDII
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Re: GDII's 1990 G-Limited
Removing the front cam cap from the exhaust cam. 2x 10mm bolts hold this on and it seams a lot of sealant too. This one needed to cut off with a razor blade.
The camshaft has a slight groove in it but nothing major. I was expecting more because as you'll see in the next post the intake camshaft has a far larger groove. I'm guessing it possibly had something to with it not being seated properly so it wasn't in the same location as the previous seal so was wearing on a new part rather than the old part.
The camshaft has a slight groove in it but nothing major. I was expecting more because as you'll see in the next post the intake camshaft has a far larger groove. I'm guessing it possibly had something to with it not being seated properly so it wasn't in the same location as the previous seal so was wearing on a new part rather than the old part.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
- GDII
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Re: GDII's 1990 G-Limited
Soooo much sealant! A bigger groove on this intake cam shaft but the seal was still working well so nothing to worry about here.
Next step is to clean all the sealant and oil off.
Next step is to clean all the sealant and oil off.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
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Re: GDII's 1990 G-Limited
If it leaks oil it can't rust
Do you have an ugga dugga gun? It helps with disassembly
Do you have an ugga dugga gun? It helps with disassembly
- GDII
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Re: GDII's 1990 G-Limited
No, just hand tools. I literally got given the grinder earlier in the week. Without it, not sure I'd have been able to progress.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
- GDII
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Re: GDII's 1990 G-Limited
This is the cam position sensor. It sits on the top of the head in the right rear behind the intake cam. On the back of the camshaft is an arm that runs in front of this sensor. For every two rotations of the crank shaft there is 1 cam position signal along with the crank position sensor telling the ECU where the engine position is and when to fire the coils.
The sensor needs a good clean. These sensors are known to leak and it's not just around the seal between the sensor and the head but through the sensor electrical plug. You can't buy the seal on its own so you need a whole new sensor if you want a new one. When cleaning the sensor I found why it leaks internally, the metal cover is just crimped over the plastic body and can rotate so the seal won't seal this connection and will leak.
Driftmotion has come up with a double seal to stop this developed for the 2JZ but it's the same sensor for the 3SGTE.
https://www.driftmotion.com/Double-Lock ... dm3814.htm
The sensor needs a good clean. These sensors are known to leak and it's not just around the seal between the sensor and the head but through the sensor electrical plug. You can't buy the seal on its own so you need a whole new sensor if you want a new one. When cleaning the sensor I found why it leaks internally, the metal cover is just crimped over the plastic body and can rotate so the seal won't seal this connection and will leak.
Driftmotion has come up with a double seal to stop this developed for the 2JZ but it's the same sensor for the 3SGTE.
https://www.driftmotion.com/Double-Lock ... dm3814.htm
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
- 4CylinderSpecial
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Re: GDII's 1990 G-Limited
This engine has to be the luckiest engine in NZ! Great attention to detail as per.
- GDII
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Re: GDII's 1990 G-Limited
I wouldn't quite go as far as to say that. At this point in time the engine will remain closed up and go in as is. So no new head gasket even though I have one, no new bearings, no new piston rings or bore hone. I will do valve seals however. It's just extra costs I don't have for the build.4CylinderSpecial wrote: ↑Tue Nov 17, 2020 8:57 amThis engine has to be the luckiest engine in NZ! Great attention to detail as per.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
- GDII
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Re: GDII's 1990 G-Limited
Things have slowed down a bit but plans are still being hatched.
One big step forwards is obtaining this full seal kit. Thanks to Thomas/GalanzaAtHeart for supplying this kit. Part number 04111-74721. It contains a large amount of seals and gaskets but not every single one. Things like oil pump and water pump seals are not in it so these need to be purchased separately. Or in my case with the water pump kit and oil pump unit.
I'll probably do a break down of parts and part numbers in the kit when I get a chance on top of the parts diagram and list of which diagram each part can be found in.
One big step forwards is obtaining this full seal kit. Thanks to Thomas/GalanzaAtHeart for supplying this kit. Part number 04111-74721. It contains a large amount of seals and gaskets but not every single one. Things like oil pump and water pump seals are not in it so these need to be purchased separately. Or in my case with the water pump kit and oil pump unit.
I'll probably do a break down of parts and part numbers in the kit when I get a chance on top of the parts diagram and list of which diagram each part can be found in.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
- GlanzaAtHeart
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Re: GDII's 1990 G-Limited
You'll put this to more use than I ever will.
That exhaust manifold gasket was a lot thicker than I expected. I'm suprised they don't put the oil pump seals in it, thought that would be a major gasket.
Keen to see how it will all fit together, I'll be keeping an eye out, keep up the good work!
That exhaust manifold gasket was a lot thicker than I expected. I'm suprised they don't put the oil pump seals in it, thought that would be a major gasket.
Keen to see how it will all fit together, I'll be keeping an eye out, keep up the good work!
89' SW20 GT w/ Gen 4 3SGTE
13.2 @ 107mph
"man this thing drives like ass" - Sun Tzu, probably
13.2 @ 107mph
"man this thing drives like ass" - Sun Tzu, probably
- GDII
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Re: GDII's 1990 G-Limited
I'm sure I'll use almost every single part minus the head gasket and the downpipe to B pipe slip gasket as that is Caldina specific.
When you look at the oil pump parts diagram you get all the seals outside of the box. So makes sense why. When putting Olafs engine back together I forgot these weren't in the set, even though I was aware they weren't I just forgot to order them. I'll be sure to document every seal going onto the engine similar to how I did the disassembly. Things should be clean so a little easier to do it without making a mess of my camera or phone.
When you look at the oil pump parts diagram you get all the seals outside of the box. So makes sense why. When putting Olafs engine back together I forgot these weren't in the set, even though I was aware they weren't I just forgot to order them. I'll be sure to document every seal going onto the engine similar to how I did the disassembly. Things should be clean so a little easier to do it without making a mess of my camera or phone.
1990 SW20 MR2 G-Limited (GEN4 3SGTE Installed)
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/
2000 AE111R Corolla Wagon NZ New Daily
1996 AE101R Corolla Sprint NZ New Selling Soon
1990 EP81 Starlet XL (Sold)
1990 EE90 Corolla XL (Sold)
Instagram https://www.instagram.com/sw20glimited/