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[Mk2] [Turbo] Exhaust Stud Replacement (possible head removal)

 
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markstevieandmads




Joined: 05 Aug 2013
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Location: Swindon, Wilts
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1993 Toyota MR2 Mk2 Turbo Rev2

PostPosted: Sun Jul 23, 2017 7:00 pm    Post subject: [Mk2] [Turbo] Exhaust Stud Replacement (possible head removal) Reply with quote Reply with quote including images

Ive been having problems with a snapped stud on my exhaust manifold (rev 2 turbo).

I originally helicoiled it and that seemed to last till a track day which must have been too much and it started blowing in that area.
Ive removed the turbo and decat already so there is a bit of access to the bottom rhs stud.

Ive tried rehelicoiling it but everytime i put some torque onto the stud it just pulls the helicoil out and doesnt tighten.
So it seems i may need to get this done properly and time insert it. Ive asked for local mobile mechanics for a quote if they can do it with the head in situ.

However, i dont have much confidence this can be done so i may have to opt to remove the cylinder head and send it to a engineering place to get it done properly.

So a few questions:
1. Is there any alternative to helicoiling apart from time insert?
2. If i have to remove the cylinder head then ive read i can do this with the inlet manifold still on it which sounds easier. Does anyone have an idiots guide to this?

Im quite confident i can get the head off except what to do with the cambelt? Can i just cut it off? Im not at all confident in fitting and timing a cambelt kit so was going to remove the cylinder head, get it sorted and then reinstall myself with new rev 3 head gasket and head bolts and then get the car towed to a specialist and get them to fit a new cambelt kit. I would then reinstall the turbo etc myself to keep costs down so the specialist will only be doing the belt and idlers.

So more questions:
3. Do i need to put the engine into any "state" before cutting the belt to remove the head?
4. Can i just put the head back on without it being in the same "state"
5. what parts do i need to do all the above?
6. Anything else i should do while the head is off?(such as rev3 inlet cam?) Any upgrades (keeping costs down so rev3 management/rev3 head is out of the question)

Sorry for all the questions but want to prepare myself!
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pbmr2
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PostPosted: Mon Jul 24, 2017 1:47 pm    Post subject: Reply with quote Reply with quote including images

If access is good then maybe possible for the mobile guy to sort it, speak to them first.

Best bet would be to take the head off and send it off for a proper repair.
you don't need to cut the belt to remove it. Just undo the tensioner and the slack will allow the belt to be pulled off by hand.

Read the BGB!! This BGB also details the correct order for undoing the head bolts and lists the correct torques for re tightening when fitting. the order of the bolts is important as it the stages they are undone/refitted.

3. don't cut the belt. read the BGB and it lists the order of things to do. TDC, remove battery, drain coolant. more or less it.

4, well you can but you have to line things up, this why TDC is used. again it's all in the BGB..

5. head gasket full kit.

6. water pump, cambelt kit with tensioners and idlers, check the crank oil seals, check the cam cover gasket, check the crank oil seal. head will need a good clean if not a light skim. also needs to be checked if it's still true.

enjoy
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Gazza_DJ
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1997 Toyota MR2 Mk2 NA Rev4

PostPosted: Mon Jul 24, 2017 2:06 pm    Post subject: Reply with quote Reply with quote including images

It's easy to set it all up even if the crank or cams move, I wouldn't worry about that. TDC is even easier to find with the head off [Laughing]
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markstevieandmads




Joined: 05 Aug 2013
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Location: Swindon, Wilts
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1993 Toyota MR2 Mk2 Turbo Rev2

PostPosted: Mon Jul 24, 2017 3:09 pm    Post subject: Reply with quote Reply with quote including images

Thanks for the info.
The problem i have is how far to go with this...

If the head is coming off then the cambelt needs to come off. If thats coming off then it maybe easier to remove the engine. If the engine is coming out then i may as well do other things that would be easier with engine out such as clutch etc.

Ive had the car 4yrs and dont know when the cambelt is due so it would be right to do this.

Also pricing wise, i can see it being more than just a head gasket kit. Wouldm it not need new head bolts (arp?).
Also would i not need gaskets like the inlet manifold etc as this would need to come off if the head is going to a shop.
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Gazza_DJ
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1997 Toyota MR2 Mk2 NA Rev4

PostPosted: Mon Jul 24, 2017 3:19 pm    Post subject: Reply with quote Reply with quote including images

You can get a complete gasket kit from Toyota for ~250 which contains head gasket, inlet and exhaust gasket, crank seals, cam seals, injector seals, valve stem seals, turbo gaskets, oil pump seals, o rings, the lot. Good value for money if you're doing everything.
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pbmr2
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PostPosted: Mon Jul 24, 2017 11:12 pm    Post subject: Reply with quote Reply with quote including images

you really need the full camblet kit with the tensioner and idler also, the old units might fail shortly after refitting. not that it will do any damage to the engine but the whole job has to be done again.

water pump is also a must and they really do fail after a belt change. very cheap to replace.

call TCBparts and speak to them about what you need. they are very helpful and may just save you loads of money.

The Toyota gasket kit is a good idea as they are excellent quality and you won't have any problems.
be prepared to maybe get the valves reseated if there is signs of wear. probably fine but another possible thing once you get it apart. the gasket kit will include the valve seals.

oh and get a new thermostat, very cheap but costly if it fails.

It can all be done with the engine in the car and an axle stand holding the engine up while the mount is off. Only if you want to go further with the refresh of the engine is taking it out needed. things like oil pump, bottom end bearings, clutch.
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markstevieandmads




Joined: 05 Aug 2013
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Location: Swindon, Wilts
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1993 Toyota MR2 Mk2 Turbo Rev2

PostPosted: Tue Jul 25, 2017 6:30 am    Post subject: Reply with quote Reply with quote including images

My first port of call was tcbparts.
Actually i was very disappointed. They dont havr the full gasket kit and dont know when they get them in. In fact their response to my emails was borderline rude/cant be bothered. I asked a few questions but it seemed they couldnt be bothered to answer all my questions. It has made me think twice about going there again which is a shame as they have been useful in the past.
After googling it seems i can get the full kit for cheaper anyway from tuningdevelopments. They emailed me straight back and seemed a lot better customer service. If im paying by paypal anyway then im covered if anything goes wrong anyway.
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pbmr2
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PostPosted: Tue Jul 25, 2017 7:44 am    Post subject: Reply with quote Reply with quote including images

to be fair TCB are so oldschool that if you don't pick the phone up you won't get top service. They do seem to struggle with the online side of things. Never had an issue over the phone.

Glad you found the gaskets though
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Gazza_DJ
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1997 Toyota MR2 Mk2 NA Rev4

PostPosted: Tue Jul 25, 2017 8:41 am    Post subject: Reply with quote Reply with quote including images

Make sure it's the genuine Toyota kit. The aftermarket ones are crap. You can get the from the Toyota dealer too, but it takes a little time as there's rarely any UK stock, it has to come from Japan. Pretty sura Hurley stock them too.
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