http://www.mahle-aftermarket.com/MAHLE_ ... lationTips

Checking Bearing Clearances from Mahle/Clevite along with lots of other interesting* info





*AWOOOGA, AWOOOGA, NERD ALERT, NERD ALERT, AWOOOGA, AWOOOGA

So following the above clarification on the clearances - here are the ones as measured:



As Chris has said the only one that is badly out is number 5 on the exhaust cam but this is also the hardest to measure as the oil groove in the cap and the camshaft interfere.

I have decided to go ahead with getting this head properly measured and then refurbed.

Chris - I will take up your offer of transport to Terry is thats ok - I'll bring the head along on Wednesday to the curry.

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GT4DC Events Co-ordinator
1996 ST205 UK

A small update:

I dropped the head of this week to get refurbished. Whilst measuring up for the final time myself I discovered an error with some of the information posted above in the thread.

When I posted this original picture:



It was pointed out that the journal caps are in the incorrect order and that the inlet caps are on the exhaust cam – as marked by the E on the camshaft.

In fact this is incorrect – the caps were in the correct order but that is not a letter E it is the number 3 and that is definitely the inlet camshaft as it has the notch in the end to accept the distributor. The exhaust camshaft has a number 4 on it in the same position.

Below shows the excerpt from the BGB stating the inlet camshaft has the slit in it.



Below is a picture of the camshaft showing the slit and the misleading letter E.



So this is reassuring in that there was not as big an error in the placement of the caps as once thought.

I carried out a final series of measurements using the plastigauge with the caps on the correct camshaft and in the correct order.



These are mostly within specification so I have decided to go ahead with this head.

Also of note the Carrilo rods arrived so I have dropped these and the CP pistons up to the engine builder.





I hope to have the engine and cylinder head back in a couple of weeks and I can get started with the fitting.

I’ve also ordered some parts to get the rear of the car sorted. Polybushes for the hub, arms and subframe as well as the spherical bearings for the arms that need them. I also ordered up brake pad pins and calliper refurb kit to sort the rear brake callipers. Lastly I have touched up the TEIN suspension with paint where they had rusted a little.

I hope to have some good updates in a couple of weeks once the engine is back.

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GT4DC Events Co-ordinator
1996 ST205 UK

Another small update.

The block has been recieved back to the engine builder from its machine work. He is just waiting on the crank now and can then build up the bottom end. It looks like I should have the bottom end back in about 2-3 weeks.

I also have sourced a set of HKS 264 camshafts which will be going in the cylinder head (hooray I hear some of you cry), I should have that back in another couple of weeks as well.

I've located a garage that will press the old bushes and spherical joints out of the subframe and arms that I will be refurbishing, once thats done I can have them powdercoated and the new bushes put in.



I also picked up some new brake pad pins and a refrub kit for the rear calipers.

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GT4DC Events Co-ordinator
1996 ST205 UK

Next update:

The new subframe bushes have arrived:



Once I have got the last two trailing arms I will be taking the subframe, diff carrier and arms to TGT to have the old bushes pressed out then have them powder coated before the new poly stuff is fitted back in.

On the engine bottom end front the machining on the engine has now been completed and its looking very tidy:




The pistons and rods have now been checked and matched and most of the sundry parts obtained for the internals:




The upper sump has also had the side sections relieved to allow clearance for the ARP hardware fastening the journal caps.



I also dropped the HKS 264 Camshafts down to the cylinder head place ready for fitting, I need to send the place the new valve stem seals from my gasket kit when it arrives, all being well I should have the head and engine back by mid May.



Finally I also ordered the remaining lower arm and fig8’s and crush tubes for the superstrut to complete the set of those as well as a full engine gasket kit, some SARD 800’s, new water and oil pumps.

I hopefully plan to start taking the car apart next weekend, and I have some research to do now on headgaskets and ECU’s.

_________________
GT4DC Events Co-ordinator
1996 ST205 UK

Hi Mike,

What's the matt red paint on the block?

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Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Kris, being an old salt I thought you'd recognise that red paint.....

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Hi Kris,

In all honesty I do not know. Don took these pictures at the weekend whilst visiting his build. (thanks Don! )

I would guess that it's some sort of anti corrosion paint.

_________________
GT4DC Events Co-ordinator
1996 ST205 UK

Is it the red dye from Magnafluxing the block?

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JP
GT4DC Treasurer

Grey St185 RC
Silver BMW E46 M3
Multicolour yawn Honda VFR400
Silver Honda Civic Type-R

Specsaver Alert!............seriously tho, as Mike says, it looks like some sort of red oxide type of paint presumably to inhibit corrosion. Its definitely not dye.

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

And I thought I did well to get the colour right

_________________
JP
GT4DC Treasurer

Grey St185 RC
Silver BMW E46 M3
Multicolour yawn Honda VFR400
Silver Honda Civic Type-R

Sorry JP, that was a bit cruel of me I thought (for a fleeting instant!) I guess you had help.

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Looks like boggo red oxide primer to me.
Used to be lead based in the good ole days of sending yer kids oop t'chimney

Woohoo!

I have the bottom end back from the engine builders.

Will post some piccies up at the weekend.

_________________
GT4DC Events Co-ordinator
1996 ST205 UK

Small update on the build.

I haven’t had the head back yet as after chatting with the engine builder and the head guys and finding out that the valve springs were a little worn we are installing new HKS valve springs in the head:



I also managed to pick up some HKS cam pulleys for a very good price 2nd hand. They have a few cosmetic marks but appear to be in fine condition otherwise:



These are the new pulleys rather than the old type which were thought to be ‘soft’ after a number of failures.

I also sourced some Sard/Denso 800 injectors which after flow testing have been found to be 860cc:



Onto the chassis I have spent a bit of time stripping the rear of the car down, the ARB is out as is the rear brakes.

The ARB is in quite a poor state and will definitely need powdercoating. The Pins on the brake callipers are also proving to be very difficult to remove.

I now have the subframe and arms ready for powdercoat, the rubber bushes have been removed ready for the new polybushes to be installed.

That’s about it for now

_________________
GT4DC Events Co-ordinator
1996 ST205 UK