Hello all - i have finally got the engine into the garage, and hopefully some time on my hands.
What i need to do now is some research into how to do this - i haven'y rebuilt an engine since my mini days so i suspect the happer and nail attitude i had in those days needs to change.

Firstly i would like to find a manual that tells me how to strip the engine and then rebuild it with forged pistons - but i know im asking too much.. so any books - reference sites etc would be nice...

Here's to a a vouage into the unknown - and hopefully soon to be known ??

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ST205




"And God said, Let the earth bring forth grass, and the earth brought forth grass and the Rastafarians smoked it."

What manuals do you have, if any? I'd start with combination of the Toyota Big Blue Books, including the ST205 supplements and a copy of the Chilton book even although it doesnt cover the ST205 its still a help.

Rebuilding an engine is still a very personal process. Getting the bearing clearances correct seems to be the trap lots of people fall into. I believe the 'book' clearances are misleading. In addition all the usual stuff applies e.g. chemically clean the block, use a torque plate when boring the block, replace the oil pressure relief valve etc. etc.

Good luck Rob!

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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 Don, thanks for the luck - ill probably need quite alot of it.. i have the toyota blue books, i dont have the chilton book - whats that one - the ST185 manual?

Luckily i have an engine rebuilders just down the road next to rollcenter, they seem a helpful bunch too, so ill probably be off to them for the odd but of advice.

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ST205




"And God said, Let the earth bring forth grass, and the earth brought forth grass and the Rastafarians smoked it."

Chiltons Toyota Celica 1994-98 Repair Manual is a more detaled read than the Toyota manuals but doesn't cover the GT-Four so its mainly good for body etc. Not essential for the engine work you have in mind. Link

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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

here goes - this is the first of my questions??

I have an HKS 1.2 mm head gasket and a set of arp Cylinder Head stud kit that have been fitted to my original engine - qutestion is - can i reuse these or should i buy new?

Ta

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ST205




"And God said, Let the earth bring forth grass, and the earth brought forth grass and the Rastafarians smoked it."

Rob, I'd get a new head gasket and you can re-use the old ARP head studs if you want to save a bit of dosh. Personally I'd use new but thats just me

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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

thanks Don.. just wanting to reuse as much as possible really.
It looks like im going to transfer the head and the turbo, injectors, fuel pump and the power fc to my existing 4, and start on the bottom end after that...

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ST205




"And God said, Let the earth bring forth grass, and the earth brought forth grass and the Rastafarians smoked it."

Sounds like a good plan m8. Don't forget we want to see the pics

_________________
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

Next question - probably a bit of a stupid one - but what tool is needed to undo the head bolts?

Anyone got a QRG on how to get this off?

Cheers - i may sound dumb.. but im happy

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ST205




"And God said, Let the earth bring forth grass, and the earth brought forth grass and the Rastafarians smoked it."

You need a splined tool to remove the head bolts

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

aha - thanks Kris, do you know what size by any chance?

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ST205




"And God said, Let the earth bring forth grass, and the earth brought forth grass and the Rastafarians smoked it."

IIRC you can only typically buy them in sets - Circa £20 from Halfrauds. I have some I think if you wanted to borrow them next week.

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JP
GT4DC Treasurer

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

i think these are arp bolts - they dont seem to be the same

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ST205




"And God said, Let the earth bring forth grass, and the earth brought forth grass and the Rastafarians smoked it."

Rob - yes looks like a non-standard part!. There is an Allen key fitting in the top of an ARP head stud if you wanted to remove it completely.

ARP head studs are all the same length so you don't have to remember where they all came from!

Think Steve's recommendation is the best way forward on the spline set, just buy a set, they are inexpensive and it's not uncommon to need one for some weirdo bolt fitted somewhere

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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

arp nuts are just 14mm 12 sided sockets iirc. no special tool needed for them.

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Pete
ST185
Basingstoke