NLSOLJA123 SVT Turbo ZX2 project

[nlsolja123]

I will continue to edit this main post for updates,

MAJOR UPDATE,,, I BENT MY ALL EXHAUST VALVES DUE TO timing skipping a tooth,,,,,,,,,,,, I currently have a PnP Focus head, and the valves are not expensive BUTm i got a Deal on a SVT head that i will be putting on within the next 2 weeks

[nlsolja123]

Just for the record this is my first and only worklog, and heres the mods and pics of it getting setup

http://c2.ac-images.myspacecdn.com/images02/94/l_3113c5eb1cf448c086481775426a9c05.jpg
http://c1.ac-images.myspacecdn.com/images02/109/l_464213f2d1f74af99a1775cce20f0e9c.jpg
http://c3.ac-images.myspacecdn.com/images01/86/l_9ac4f4d0b63b0cf61a51e213058fed3e.jpg
Engine,
Svt focus rods and pistons
Focus head, ported and polished by me,
Zx2 intake cam
focus exhaust cam
Te04h turbo ( gude turbo)
Tial style wastegate
Greddy style bov
42lb injectors
pro-m maf 70mm in a 73mm housing suck thru at the moment.
AFX underdrive pully
Borla muffler to basani dual tips

Body
Vis racing fenders
Urethane buddyclub front
zxtuner carbon invader hood
Vis carbon trunk
evo rear bumper
Invader sideskirt (awaiting install)
m3 accord mirrors

Suspension
18 enkie wheels
drilled and slotted brake rotors
21mm rsb
es bushings thruout randomly lol
Nopi brand adjustable coilovers ($70)
Tokico shocks
reactive strut tower bar


Turbo kit $200 deal YEAHHHH
http://c3.ac-images.myspacecdn.com/images02/45/l_6c3662fad2684e9cae4f821df4324116.jpg
http://c2.ac-images.myspacecdn.com/images02/2/l_46746fea1c6e419c98debe1c3d7c9c85.jpghttp://c3.ac-images.myspacecdn.com/images02/34/l_46e28085691d419396cdb88f71067566.jpg

SVT Internals $200
http://c1.ac-images.myspacecdn.com/images02/4/l_d9635271489643cc91780296681dadac.jpg

the tear down begins,
http://c4.ac-images.myspacecdn.com/images02/20/l_6f90ec34e90d4e21af1a3f965264358f.jpg
http://c2.ac-images.myspacecdn.com/images02/20/l_7bd2ff38338f4682b59a31006c1d3bd9.jpg
http://c1.ac-images.myspacecdn.com/images02/60/l_a66c87b1b6db4543ad38ea7545297c90.jpg

All done
http://c1.ac-images.myspacecdn.com/images02/6/l_2537c5e3836246f99640fe2d84cc48b8.jpg
http://c1.ac-images.myspacecdn.com/images02/54/l_6df27a6cf94946c29fed2814292b6738.jpg


Heres a OLD pic of the blue paintjob i had 3 yrs ago
http://c1.ac-images.myspacecdn.com/images01/76/l_c832824e69e68a4cf6e3e450eab52504.jpg

[dareall]

nice score on the turbo kit :judge:

[nlsolja123]

ya its a focus kit but is to good a deal to pass up

[zetec00]

Where'd you get the SVT internals? And did you install them yourself?

[nlsolja123]

i got them from a guy on the focusfanatic forum and i have done 99% of the work on my car, the other remainder is like welding (stepdad does it, hes a 40 yr machinest) and when i get mad and call someone for help

[zetec00]

Cool, how difficult was it to install the rods & pistons?

[The_underclassman]

Cool, how difficult was it to install the rods & pistons?
Rods and pistons are really easy to install. All you need is a piston ring compressor and a torque wrench in ft lbs. The crankshafts are the same and all you need is std. size rod bearings for a Zetec. http://www.amazon.com/Powerbuilt-648434-Wrinkle-Piston-Compressor/dp/B001CZASD6
^ That's the one I have

Nsolja, I really like your ZX2 and what you're doing to it. Great work. Who made the downpipe?

[zetec00]

Rods and pistons are really easy to install. All you need is a piston ring compressor and a torque wrench in ft lbs. The crankshafts are the same and all you need is std. size rod bearings for a Zetec.

Thats what I had figured, but just wanted to double check.

[nlsolja123]

the downpipe from the turbo was just bent by my stepdad and welded on, he did it at work. I appericate the comments. I have been a member of the forum since 2003,

im selling the turbo and the up pipe to bolt to the collector, as well as a section of the downpipe,
I got a larger ebay turbo i plan to put on in the next coming month. its a t04e .50 intake and .63 exhaust,
my stepdad is going to weld a t3 flange to the header im using, and tap my header to fit my external wastegate right on it. Currently my wastegate is near the oil pan with the turbokit (screamer-pipe style).

[nlsolja123]

And just to show how easy it is to install pistons, i did all the motor work with the motor in the car, the only thing i can say isnt perfect with my motro as of right now, is the exhaust cam needs adjusting, theres a little tapping, so when i upgrade cams ill check the tappet/cam clearances

[corbygasm]

And just to show how easy it is to install pistons, i did all the motor work with the motor in the car, the only thing i can say isnt perfect with my motro as of right now, is the exhaust cam needs adjusting, theres a little tapping, so when i upgrade cams ill check the tappet/cam clearances

do not mean this in a dickhead way, but what about the oil pressure thing? did you get that figured out?

[zetec00]

How did you install the rods & pistons with the motor in the car?

[nlsolja123]

Ya corby the oil pressure problem was a faulty relief valve inside the oil pump, what gets me aggravated is i ask for a little help and people treat me like a newbie asking if im sure the filter tight enough. but the relief valve was causing the oil pressure to hit around 150 at idle,

i installed the rods and pistions in the car as the pics show, i took off the head because i planned on using the focus one that I ported and polished. and i dropped the oil pan and you can ge to the rod bolts, once the rodbolts are off u can just push the pistons up since the heads not there, I honed the block in the car 2.


THe reason I did the motor rebuild is the car smoked for the past 2 yrs, i figured it was rings but, in august i ATTEMPTED a trip to the ZX2 S/R junkyard in alabama in srch of a new set of sideskirt due to one of mine being shattered, well on the way there i was going up the mountain and bam ,,,,i shattered a valve, i ddint know it at the time but i knew something was wrong, when i was burning more oil than my old rx7 with used premix gas. I did drive my escort homeafter the valve shattered like a 2 hr drive, these cars keep running even when there at there worst trust me.

[zetec00]

Thanks for the info. Car looks good man.

[nlsolja123]

thanks for the ? and comments

[nlsolja123]

I got the manifold installed today, it was a sucess except for the vac. leak,

[nlsolja123]

blew my motor today cruising at 2k no boost, timing jumped, i tthink. i almost got the head off around 7 and called it a day

[yellow2000S/R]

How'd you blow the motor if timing jumped? You have aggressive cams or something?

[corbygasm]

in for da pics!

[carbonzx2]

blew my motor today cruising at 2k no boost, timing jumped, i tthink. i almost got the head off around 7 and called it a day

damn, that sucks. im in for pics too

[nlsolja123]

got the top end taken all of,,,,,,,i have a stock zx2 intake cam and a focus exhaust cam,,,,,,,The total damage that was done was all the exhaust valves bent, timing was 1 tooth off on the top end when i checked TDC before the tear down,

I have SVT focus pistons and they have no exhaust valve cutouts/reliefs and it bent all the exh valves,,,,,,,,,,,,,good thing is i got my turbo off and im going to be putting the bigger one on,,,, IF I dont put a SVT Head on,,i may decide to do this

[nlsolja123]

bump read first post

[joshalabama]

Sorry to hear that man, good luck in getting this done. Let me know when you do or if you need help and I can make a trip up there. Then as soon as your ready we will set up a tune date.

[inis]

weird because without the svt head, the svt block with a standard head is less compression then a standard zetec block.

svt complete block/head: 10.2:1
stock zetec: 9.6:1
svt block w/ standard head: 9.3:1
stock block w/ svt head: 10.6:1

hmmm something is fishy.

[zetec00]

Yeah I don't think, even with the SVT pistons & standard Zetec head, that it should be an interference motor. Something doesn't sound right...

[nlsolja123]

THE SVT has no exhaust reliefs in the pistons,, and i felt the binding when i turned the crank with the motor together, i got a pic as well

http://c2.ac-images.myspacecdn.com/images02/69/l_b866e580be724daab9f80c06d93fe309.jpg

[zetec00]

Yeah I knew about the SVT pistons having no reliefs for the exhaust valves, but I just thought it would still be a non-interference motor. Hmmm, guess not.

[nlsolja123]

ive talked to a machine shop and they can cut a valve relief for 15$ a piston

[nlsolja123]

any one want to buy a pnp head with no ex valves, for 75?

[The_underclassman]

post some pics or send me some. I want to see each intake and exhaust port, along with the combustion chambers

[corbygasm]

http://zeebone.com/gallery/d/68754-2/DSC_4412.JPG

[nlsolja123]

Ill take pics for you tomorrow

[99fordzx2]

http://zeebone.com/gallery/d/68754-2/DSC_4412.JPG

When the valves slap the pistons like that is the piston still useable? Would the damage done cause a hot spot on the piston? Would pistons like that need to be resurfaced or something?



-D

[nlsolja123]

not being rude 99 but theres a hole in that piston,,,,,,, but in my case there is just scuff marks that can be smoothed out.

[carbonzx2]

not being rude 99 but theres a hole in that piston,,,,,,, but in my case there is just scuff marks that can be smoothed out.

i was thinking the same thing

[corbygasm]

the picture is just a simple comparison between the two pistons lol.

[99fordzx2]

Didnt notice the hole, but just based on the valve slap on the pistons.


-D

[1981gMachine]

subscribed

[inis]

http://zeebone.com/gallery/d/68754-2/DSC_4412.JPG

just a thought, but you might have a boost leak there.... just sayin.

[corbygasm]

are yall all retards? i posted that pic, not him.

[yellow2000S/R]

are yall all retards? i posted that pic, not him.

Ur a ra-tard. Postin pics in other people topics. Shame on u!

[99fordzx2]

are yall all retards? i posted that pic, not him.

WTF, I was just curious about if the pistons are usable if the valves ever hit the piston, minus the hole. And your pic illestrated my question nicely. But yah, I did know you posted the pic numbnut.


-D

[corbygasm]

WTF, I was just curious about if the pistons are usable if the valves ever hit the piston, minus the hole. And your pic illestrated my question nicely. But yah, I did know you posted the pic numbnut.
-D

obviously talking about inis you numbnut lol.

[Blue ZX2]

When the valves slap the pistons like that is the piston still useable? Would the damage done cause a hot spot on the piston? Would pistons like that need to be resurfaced or something?



-D
To ACTUALLY answer your question. It really depends on how bad it was. But for me (if the valves break) I would not reuse the pistons simply due to the fact that they were subject to forces they were not designed for. I would rather replace them rather than have them fail later on down the road due to stress fatigue or some other BS. On the other hand I can be sort of anal and some may find it necessary but I like to keep my cars to aviation spec therefore they would be tossed. I don't like to gamble with parts.

Also if you would like to reuse them the dents would cause hot spots and would need to be buffed out which could be done with high grit sand paper, crocus cloth or something of that nature.

[nlsolja123]

I was considering having valve reliefs cut into the pistons from a machine shop

[ChrisZX2]

Instead of risking it by reusing pistons that are possibly structurally unsound, I would really just get new pistons. Ether stock ZX2 pistons that already have the relief cut into them, or forged pistons that (combined with the forged SVTF rods) would really allow you to turn up the boost.

[The_underclassman]

The smaller combustion chambers of the SVTF give it a static 10.2:1 compression when paired with a SVTF head gasket.. a regular Zetec head with a SVTF head gasket and SVT bottom end should get you in a much safer range for boost.
Reg Zetec HG - .027"
SVTF HG - .041"

Zetec combustion chamber - 48cc
SVTF combustion chamber - 42cc

For boosting, you'll want a lower compression ratio than 9.6:1 (around 9.0:1), but you'll either be at 10.2:1 or 10.6:1 depending on which head gasket you choose with the SVTF head. If you can afford the gas for the higher compression ratio, by all means don't let anyone hold ya back.

[nlsolja123]

Johnzx2,,,,,There are ZERO pistons that fir the svt rods,,,,except the svt pistons that is,,,,,,

and i have turbos and Nitrous so im debating which to use but most likely the turbo,,,,i can get aviation gas really easily. its like 105 octane and is 3.50 a gallon..

[99fordzx2]

To ACTUALLY answer your question. It really depends on how bad it was. But for me (if the valves break) I would not reuse the pistons simply due to the fact that they were subject to forces they were not designed for. I would rather replace them rather than have them fail later on down the road due to stress fatigue or some other BS. On the other hand I can be sort of anal and some may find it necessary but I like to keep my cars to aviation spec therefore they would be tossed. I don't like to gamble with parts.

Also if you would like to reuse them the dents would cause hot spots and would need to be buffed out which could be done with high grit sand paper, crocus cloth or something of that nature.

Thanks.


I was considering having valve reliefs cut into the pistons from a machine shop

Cool, didnt know you could do that.


obviously talking about inis you numbnut lol.

Next time specify noob!



-D

[Blue ZX2]

Johnzx2,,,,,There are ZERO pistons that fir the svt rods,,,,except the svt pistons that is,,,,,,

and i have turbos and Nitrous so im debating which to use but most likely the turbo,,,,i can get aviation gas really easily. its like 105 octane and is 3.50 a gallon..

Yeah you are going to want to steer clear of the AV gas because it contains high levels of lead (thus how they bring up the octane levels) and it will build up in your engine and clog it all up. When we do 50hr inspections of regular planes the spark plugs are coated with lead deposits. So yeah stick with unleaded because your engine is not meant to be ran with it. Or unless you feel like cleaning everything out every few hundred hours of operation which I doubt you will.

[nlsolja123]

thanks blue,,, didnt know that,,,, i ran it on my turbo rx7, the local av gas is 105 low lead, made my rx7 run good but those are different animals

[Blue ZX2]

No prob mang, even though it says LL or low lead its still MASS amounts more than regular gas. I use to run 110 leaded automotive gas which is lower lead content than LL AvGas in my ZX6R but im convinced the 13.5:1 compression ratio kept that all blown/burn out lol.