Overlord475: 1988 SETA 2.7i Build Thread (Turbo Prep)

[Overlord475]

End of Teardown Day #4

Mostly just cleaning stuff:



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My cheater bar set up to get to 302 ftlb on the front crank bolt.
The larger piece and adaptor on the bottom is to fit over my large torque wrench

[Overlord475]

Getting back to the teardown/cleaning this afternoon!

Ordered some AN fitting from Earl's to pre-prep my pan for turbo oil return.

[AlphaE]

SUPER curious about the chip?! Have a seta converted to i myself. W the green top inj also. Hit me up w any questions, not that you need it, seems you got it all covered.

[Overlord475]

What coolant ports did you have to weld shut?

The head casting's unused coolant reassess are welded as they are a weak point for blowing the HG under boost if the head lifts at all. When un-welded the head is allowed to flex which creates a great place for the HG to blow.

Info:

http://www.r3vlimited.com/board/showthread.php?t=122833

Not my head, but a good example:

[Overlord475]

End of Teardown Day #3

Stoned the block deck, removed the oil pan & prep'd for new gasket, and removed the front main seal carrier:

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[blue plates]

What coolant ports did you have to weld shut?

[E30NJ]

nice!

[D J]

Very nice I'm about to have the I swap done on my seta here soon. I'm going to be watching this one.

[Overlord475]

End of teardown day # 2:



About to pull the head:



There was a lot of carbon build up on the pistons, but the factory cross hatching still present in all 6 cylinders:



After cleaning pistons (deck still to be cleaned and stoned):

[Overlord475]

New wheels on the way:

16" x 8" / 4x100 / 20 ET / CB 73.1

Picked up a set of these from Black Forest to take care of the 73.1 to 57.1 CB issue:

http://store.blackforestindustries.com/alceriexdi73.html

And these are the tires I'll wrapping them in:

http://www.discounttiredirect.com/direct/tires/continental/product/submitProductSize.do?pc=26160&tmn=ExtremeContact+DWS&typ=Passenger%2FPerformance

[Overlord475]

It has begun!

Teardown day 1:

[squidmaster]

Looks squeaky! I know you're probably excited

[Overlord475]

2.7i Swap Info:

885 Head (Prof. Clean/Checked/Welded Coolant Passages/New Valve Guides/3 Angle Valve Job)
ARP Head Studs
173 ECU w/ SSSquid 2.7i Stage 1 Chip
Gates Race Timing Belt (BLUE!)
m50 17.5# Rebuilt Injectors (by MEPEH)
HiPerformance Silicon Vacuum Hose Kit
Silicon Coolant Hose Kit
M20B25 Intake Man., AFM, 7k Cluster, etc
Misc. Required Parts (PelicanParts)

Update (3/1/14):

Head back from cleaning and disassemble. Looks awesome!
Now out for Coolant Passage Welding



There's a bit of grease on the surface from an old HG that was laying on top of it for welding reference:

[Overlord475]

Just performed a leak down test, and all looks good.

Here are the results (cylinders in firing order):

1 - 13% (Rings)
5 - 10%
3 - 5%
6 - 13% (Rings)
2 - 10%
4 - 15% (Rings)

Leak percentage should be preferably between 10% and 15% or lower. But, technically it is acceptable to have leakage all the way to 40%, but.... questionable.
It is best if each cylinder is within 5 to 8% of each other.

It should be noted that the above test was performed on a "cold" engine.

If the engine is allowed to heat up prior to the test (preferred, I just don't like burning myself) then all the metal expands (rings specifically) and creates for better sealing. The leak percentages will be even small with a heated motor.

Most of the cylinders barely made it into the green "Low" section. Good sign!

A leak down should be performed prior to any major upper end (head) work to determine the general health of the engine. It would be dumb to put a new head on without rebuilding the block if the rings were bad.

Used the HF leak down gauge set:

[Overlord475]

Fixed a few rust spots and repainted. POR 15 is the stuff!

Also repainted the black strip around the bottom: