Well, you're here because you followed the links either from the turbo installation, the head modification page or the from the modifications list page. Either way, the story continues here...

I am now rebuilding the engine for a second time due to some problems with the original cylinder bore being too tight for the forged pistons. The custom made JE pistons landed up getting ruined (pictures coming) and had to be trashed. I got fairly disgusted with the situation and decided to go back to all Toyota parts...I also got another machine shop to deal with. The new guys are great. They are Kingsley Automotive in Nashua, NH (phone 603-889-3844). The owner (Len) and his coworkers (Brian and Mike) have been building race engines for quite sometime now and know all about foreign and domestic engine building and modding. They are really great guys and a wealth of information!

If you live anywhere in New England, I would seriously recommend dealing with the guys at Kingsley. Compared to who I was dealing with before, the difference is tremendous. Their level of knowledge is completely different than the usual machine shop. They care enough to do the job right! (That's getting harder and harder to come by these days)

Because of the improper cylinder bore that lead to the piston failure, it also caused a bad wear ring around the top of the cylinders. This was due to the piston cocking so much at the top of the stroke that the front and rear of the cylinder were worn away so much that it couldn't be cleaned up with more boring. This means I have to locate another block! One was located at a nearby junk yard and it checks out. Therefore I am in business again!

The new plan is as follows:

• New Toyota 0.50mm oversized cast pistons and rings
• Reuse stock rods & crank (they are both forged)...using all new Toyota bearings. No more Federal Mogul!!!
• Modified 5S-FE cylinder head with 1mm oversized Ferrea valves; Head was also ported & polished (Details on head mods)
• Camshafts reground by Crower (New camshaft specs)
• Black powder coated valve cover (installed picture)
• Target boost is 10psi
• Boost controlled with a Turbo XS mechanical boost controller inline with the HKS pop-off valve (Picture here) (Picture #2 here)
• Fuel pressure controlled by an Aeromotive regulator (picture of installed regulator)
• Modified fuel rail (to allow external fuel pressure regulator) (picture of fuel rail connection)
• Walbro high flow fuel pump (pictures of pump mounted in modified bracket)
• MSD Boost Timing Master to retard timing based on boost pressure
• Toyota metal head gasket (again)
• Brass freeze plugs from a Mitsubishi engine

As of Sunday 5/4/2003, the car is up and running again! After triple checking everything all day Saturday, I went out Sunday morning and it started right up! Needless to say, I am pretty damn happy! The engine is running strong and very quiet. The only thing you hear is the subtle rumble of the exhaust.

After I get the first 500 mile break-in done, I will be adjusting the boost pressure. Until then, I am babying it. First oil change at 250 miles...next at 500!

Here's come pictures taken during the rebuild and install...enjoy!