$2000 Budget Rebuild

[AfroBacon]

I have a $2000 budget and an AWD Eagle who snapped its timing belt.

My ultimate goal is to be able to handle 500HP; but for now I just want to get it up and running again.

Here's my parts the so far: I'll be reusing the stock turbo (for now) and have a replacement crank already (if needed)

-Mahle 4032 Pistons (I run these on my 3S and love them, hoping they work just as -well on the DSM.)
-Eagle Rods
-ARP Main/Head Studs
-Cometic Gaskets

All work (minus machining) will be done by me. Having not been into DSMs for a few years I'm sure there are better options out there; not to mention I probably forgot a few things. So any input will be extremely helpful.

[JacksonAuto]

I would consider a different set of pistons. The Mahles are not what we call a "turbo friendly" piston. I've seen several engines come through the door that had Mahle pistons with collapsed skirts not related to abuse or poor machining. Just a weak piston. Better options would include Wiseco and JE.

[bryanwheat]

Supertech pistons are a good budget piston. They are like 375 for a set. People used to run the Mahle pistons back in the day in these with good luck. I am not sure if the newer ones are lower quality or not.

[BeeRacer930]

What are your plans for the head? Did you smack valves at all?

[Solace Lost]

I'd say 2k is plenty of cash if you already have those parts. Maybe pick a different piston choice as stated above. I actually just bought a 6 bolt shortblock with all the goodies for under a grand. So you could always look in the classifieds for built blocks. But after its all said and done, you should have plenty left over to get a better turbo.

[AfroBacon]

I've read a few good things about Wiseco pistons; and they seem reasonable price-wise. Any thoughts on those?

Are there any hidden problems I should look out for during the rebuild? Parts that are hard to replace with the engine in (On the 3S its practically everything)? Any and all help is greatly appreciated; I'd rather do the right the first time

Originally Posted by BeeRacer930

What are your plans for the head? Did you smack valves at all?

I was told it smacked a few valves and those valves have been replaced; however, giving the condition the motor was kept in for the last year I want everything look at with maybe some port and polish. If you know any decently prices shops around MI let me know.

[My1GLaser]

I like my Wisecos. They looked great when I pulled the head a couple months ago after 18k of abuse! PTW clearance can be pretty close on them as well and you get less piston slap than on some that recommend larger clearances. This was from research I did 4 years ago when building my motor.

I am running 9:1 CR which worked well even when I was running just pump gas a couple years ago. Now I blend with E-85 and I am very glad I got higher CR!

Do a BSE. Get the block decked also if you're running an MLS. Do oil port mod 1 while the head is off. (BogusSVO did a few good write ups on 4G63 builds) Don't cheap on the oil pump. Don't waste your money on the ARP main bolts. Its unnecessary at that power level and really requires a line bore on the mains. Look into Prothane motor mounts while the engine is out. Make sure the hoses & fittings going into the steering rack don't leak. Its a bitch when the motor is in.

[BogusSVO]

What valves were used for replacement of the bent ones?
If not OE "6T" valves or a stainless steel, I would have them changed out... again...

What cams and valve springs are installed?

[valencia1510]

Originally Posted by Solace Lost

I'd say 2k is plenty of cash if you already have those parts. Maybe pick a different piston choice as stated above. I actually just bought a 6 bolt shortblock with all the goodies for under a grand. So you could always look in the classifieds for built blocks. But after its all said and done, you should have plenty left over to get a better turbo.

I agree..u have a pretty good start for this rebuild..if u do swing for new pistons im using a set of Ross pistons for my 2.3 stroker...i have guys that highly recommend Manley or Wiseco..so in alot of cases its preference. U look around enough you can get some pretty good prices for a built short block for under a grand..i traded my precision 6266 that I bought off a buddy for $650 for the built 2.3stroker (shortblock) im currently pushing

[Gus@RRE]

30k of abuse out of my Mahle pistons so far.

[AfroBacon]

Updated Parts/Mod list: (I'm sure I can find better prices for a few things)
$443 - 9.0:1 Wiseco Pistons Link
$349 - Eagle Rods Link
$96 - ARP Head Studs Link
$125 - ACL Bearings (incl. ceramic coating) Link
$190 - Oil Pump (OEM)
$84 - Timing Belt (OEM) Link
$80 - Poly Motor Mounts
$75 - Cometic Gaskets
$60 - BSE Kit
Headwork:
$? - Oil Port Mod
----------
$1502

I haven't done any research on this yet; but I do have a spare set of Mahle 6G72TT pistons. Does anyone know how possible it is to throw these into a 4G63T?
...I'm not getting my hopes up.

I'll keep my eyes on the classifieds/ebay for something already built. I won't be jumping into it for another month or two so that gives me some time to find something.

Originally Posted by BogusSVO

What valves were used for replacement of the bent ones?
If not OE "6T" valves or a stainless steel, I would have them changed out... again...

What cams and valve springs are installed?

The farthest I got into the engine was opening the hood and seeing rust on the cylinder walls; the head was tossed into the trunk not looking much better. As far as what they used; I can't imagine anything other than stock, that's if they even replaced them.

[My1GLaser]

Extremepsi.com has those pistons for $443 & rods for $349.

Oil port mod can't be more than $20. I've done it myself for free on a couple heads. (before any machine work in case you slip)

I'd look into new timing bearings & tensioner also.

[ViciousLord]

I like the low expansion of the Mahle's 4032... not too many companies offer 4032 aluminum pistons... I personally don't like JE, I've known too many people that have had severe piston slap.

I wonder what kind of aluminum stock evo pistons are made of... Anyone know?

[My1GLaser]

I believe 4032 is what Wiseco uses...I went with the recommended .003" PTW clearance. Well it was actually .0025 and then the coating wears off the skirt and it ends up at .003"

[AfroBacon]

Thanks for all the help; after these parts I should have least $500 after looking for some lower prices, classified, etc. Hopefully this covers any misc. parts and machine work that needs to be done.