Progress Log- Santas List

[Benckj]

Day 1 Prepare

I've had a maintenance/ mod list which has been growing over the last 2 years. Started with hitting the 100k mark and needing to do cam belt etc on front end. Trying to kill 10 birds with 1 stone decided to add to the list and hit it all on go. Got 3 weeks off over Xmas so thought that was the time to give it a nudge. Have listed what each part will cost given my shopping & trading list over past couple years (approx $2,000 total).

Plans are to complete;
1/ OEM tensioner, idler, Gates cam belt, adjustable cam gear, WP. ($300)
2/ new OEM clutch + clutch cylinder, braided line & DOT 5.1 + solid roller clevis mod. ($320)
3/ install t3/t4 turbo with new oil lines & actuator ($300)
4/ exhaust work incl bypass valve ($200)
5/ CRW upgrade CV axle joints ($125)
6/ refurb alt to 120amp ($100)
7/ new drive belts, ancillary hoses, maint items (ie fuel filter, axle seals, outer CV boots, etc) ($120)
8/ PGP waterborne to re-shoot whole car ($150)
9/ Machining, turbo adapter, new studs and gasket kit ($450)

I'll try and keep this thread updated as I progress with list. I'm not the best for pics as my hands are generally greasy so you may need to see between the lines. Using my phone for updates which can be frustrating at the best of times. Any hints on adding pics?

[Benckj]

Pic attempt using iphone.

Can't seem to add files using attachment tab or drag & drop function. Might have to resort to PC.

Day 1- set up temp workshop and get car jacked up. Tools polished & rags on display.

[Alsw20]

What turbo are you installing?

[Benckj]

T3/4 with internal WG. Corrected above.

Turbo should make use of the stock ECU fuel being dumped in. Still need to sort adaptor manifold and V-band DP. Once running I'll chuck on dyno to check AFR's.

[GDII]

It will be interesting to see how these mods work out. Wouldn't it be better to sink money into a new ECU than painting the car? If you are upgrading the turbo and you already have water injection you would see far better power gains with proper fuel control rather than making the stock ECU to freak out when you add more air.

[Benckj]

Agreed EMS is on the cards for next upgrade. Only doing paint as getting all materials for free and car will be down for couple months while I sort out my list above. Turbo I'm installing is a small step up and I plan to use EBC, WI and cam gear to tune for max 300whp. If I want more hp later on mechanics will be done and EMS will be next investment.

Not a lot of $$ being spent here as I'm still working on building garage each morning. Edited first post with money spent on each part. Lots of savings here from trades & deals. Hope to recoup some funds from selling ct20b when I'm done and happy with T3 set-up.

[Benckj]

Day 2
Fluids drained (coolant, a2w, gearbox) IC removed as most vacume engine bay hoses. Both rear hubs started with suspension disconnected and axle nuts loose. Lower chassis member loose and ready to drop. LH axle pulled and debating if I should remove completely for CV joint upgrade.

[JasonFriday13]

Getting an ems is dependent on the setup. If the injectors and cams/gears are stock, then a mild turbo package will probably still work on the stock ecu (got to check afr's before any serious driving). However I would be doing the ems first, I did even with a 3sge.

[Benckj]

Have a local dyno and Tuner who is familiar with my car do will throw on machine and check AFRs through range. If I can get a reliable 300whp which should break me into 12s at 1/4 mile I'll be happy enough.

[Benckj]

Day 3- removals before drop

Made good progress today for an hours work. Bit cooler outside so spent more time on chainsaw and tractor working on garage build. Tomorrow I need to go into work so little progress on car front. Hopefully can drop engine by weekend and start on exhaust/alternator mods next week.

Removed axles, coolant lines, shift linkage, clutch etc. Going quite easy as I upgraded fluids and hoses when I got car over from Japan. No rust in Central Otago and since I copper coated threads when doing bushes 2 years ago everything is in good shape.

Starting to look like a TM find.

[Benckj]

Day 5

Had some Dam work yesterday and being New Year's Day not much progress today as moving rather slow in between naps.

AC compressor disconnected, starter wires, side braces removed and engine hoist positioned. Wind blew a gale last night so had to prop the gazebo walls again and tie off to trees. Got to sort out more Dam stuff tomorrow so hopefully ready to drop engine on Sat.

[Benckj]

Noticed previous posts dissapeared along with pics but understand Charlie is having some issues trying to relocated server up in the clouds.

Anyway plugging away with this extensive list Im starting to gain a bit of traction. This is only one project I'm working on so it is going slow as I expected. Aiming for March to complete.

Engine & trans removed and currently being split apart. Pulled alternator and brought into local shop for testing & rebuild, new exhaust is tacked together for checking clearance. Neighbour is setting up DP for t3/4 v-band outlet and is working on manifold.

[Benckj]

Good day today. Split trans from engine, removed clutch and covers from timing belt. Pulled ct20b off including all feeder lines. Pays to soak bolts with penetrating oil for couple days before hand. No problems breaking anything loose including crank pulley.

Everything is in decent shape although absolutely filthy with dirt & debris. Need to remove timing belt& bearings up front then have a good clean up before reassembly.

Neighbour making good progress with exhaust & DP. Going to check clearances with crossmember in then start final welds. Getting an adaptor manifold from the 20b to t3 made up.would like to keep as short as possible. Hard to believe this turbo will push more air as its lighter and smaller.

[Benckj]

Not a great deal of progress. Exhaust was checked and completed. Working on DP mod now. Measuring up turbo lines and fittings required especially onto oil feed off block.

Cleaned up trans and gave it a lick of paint. Not best job in the world but only spent an hour, couple cans of degreaser and rattle can of silver metallic. Had some leakage from axle seals so always planned to replace. Still left gooey mess. See if I can post a pic.

Before




After

[Benckj]

Found a crack in the exhaust gasket between manifold and turbo. Anyone have a good one to send to me?

Don't really want a new one as I have to mod by chopping center "twin entry" bit out.