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Discussion Starter · #1 · (Edited)
Madchyers Turbo IS300 v2.0 Rebuild *Holset, BC, Eagle, JE, AEM Goodies Inside*

A few months back I started a build thread of my initial setup you can see here: My 03 NA-T IS300 *rebuild bound*

There's way too many pictures to scroll through on the first page, so I'm going to start this thread and update this one from now on as I rebuild the current motor in the car now...

The story
Well, I had been sent to the CA state referee for being boosted in good ol' Southern California...So for a couple months I ran stock, took off the kit, got it to pass BAR and the next day the turbo kit went back on. She ran strong, a little lean up top under full boost so I babied the throttle until I had time to install the new standalone. About a month ago I driven to my friend's house a couple blocks away, his little brother and friends were wetting themselves over the turbo kit (out here it's very rare to see a boosted IS300) so I got cocky and took them for a ride. Launching 1st through 3rd, getting me and the passengers excited. Nothing happened, motor felt stout once I took them home. Later that evening I was driving the IS300 home from their house, and as soon as I got infront of my house RPMs drop to 200, wtf? Car starts bogging/hesitating, wtf? Then the knock, the dreaded knock...This isn't good, check engine light starts flashing on and off, this REALLY isn't good. Car dies. I let it sit, turn the car on and she barely turns over, and the knock got louder and louder, so I shut it off pushed it next to the curb and decided to look at it the next day. Next day comes around, I scan with OBDII to see what codes are thrown. P0300, P0301, P0302, P0303 - multiple cylinder misfires in cylinders 1, 2, 3. Motor is busted, oil coming out from inbetween the turbo manifold and the head. GREAT...Time for a rebuild.

Bottom End
I purchased a used GE bottom end, had it bored and honed .020 over and I ditched the GTE internals I had sitting and waiting, sold them off and decided to go with something stronger. Initially I had almost purchased Eagle rods and JE .020 over forged pistons. Then I changed my mind and went with something stronger again, not much, but better. I purchased Eagle ESP H-Beams and forged JE pistons, .020 over as well. Then my buddy who has been helping me with the build showed me a thread over here talking about the significant gains through using JE's high comp pistons, so I went ahead and exchanged the ones I had and received the high comps :) New gasket kit and main seals have been ordered as well.

Headwork
I also had purchased a spare head, had my friend port and polish it, had my machine shop hot tank it and do a full 5 angle valve job with copper valve seats. Valvetrain has been replaced with a full Brian Crower valvetrain. 264/264 cams, GE intake side valves, GTE exhaust side valves (exhaust ports have been slightly ported over more to fit the slightly bigger supra valves in), titanium valvesprings and retainers. Also had the lower/upper runners and throttle body ported as well for better airflow. ARP studs have also been installed.

Headgasket
So we had been held up on this issue. We needed something thick, really thick for the amount of power I am looking to squeeze out of this motor. We wanted something around 3mm of thickness for the headgasket, and all of the aftermarket companies that made them weren't more than 2.5mm in thickness, not to mention they were costing atleast ~$500 or more...So we researched. Titan Motorsports' +2000hp Supra uses 2 GTE headgaskets stacked and riveted, and stacked together would be as close to 3mm of thickness as we could get. So we went with that route, 2 GTE headgaskets copper sealed and re-riveted together, perfect. With the stronger forged internals and plans to run methanol, 9.9:1-10:1 compression ratio is what we are seeking. This will do just fine.

Turbo
Decided to ditch the generic XS Power T61 and upgrade since I have dumped so much money into building the motor for mas power. Purchased and rebuilt a Holset HX40 Super, again, a lot of positive feedback from SupraForums, so we decided to give it a shot. It's also ceramic heat coated good up to 3600* F. The internal gate has been taken out so we can utilize the external gate on the turbo manifold. Since I'm on the subject we are going with a Tial 44mm wastegate and will be recirculating into the downpipe. Dump tube was cool for about a month, but after that, just too obnoxious. For the rest of the kit, we will be using 3" charge pipe from the throttle body to the intercooler (30x7.5x3 - perfect fit on the IS300, fills up entire bottom grill and needs no crash beam modification), and from the intercooler to the turbo we are going with 2.75" pipe. The downpipe will be custom made, as well as the exhaust. 4" pipe will be used to make the exhaust system, and a Magnaflow stock looking muffler with the tip cut and replaced with a smaller one all painted with high temp black paint to retain the "stock" look.

Engine Management
I purchased the AEM v2 standalone ECU with Dezod Motorsports' PnP harness for the IS300 ECU. I want to have a daily driven tune ~500hp and aggressive tune ~700hp, I have a friend who has just been hired by AEM as a tuning specialist, so I doubt there will be any issues here.

Fuel
I have a rising rate fuel pressure regulator to be installed as well. Will most likely use NA Supra injectors or WRX injectors. Reasons being 1) driveability, this car is going to be daily driven. 2) cost. 3) can be maxed out with meth injection and will easily see +700hp. I already have a Walbro 255 fuel pump installed. Will also be using AEM methanol injection kit, and since the car will be daily driven, 91 oct pump gas will be used.

Transmission
R154 with a custom 1 piece driveshaft from thedriveshaftshop.com I've yet to decide a clutch/flywheel setup as of now, we're mainly just getting the motor finished being built before we cross this road. Perhaps down the road a V-series will be installed, but for now the R154 will do just fine.
 

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Discussion Starter · #2 · (Edited)
Taking off harnesses/bolts/nuts/etc. in order to get that hunk of junk out

Intake manifold and throttle body out, lower runners still on

Mmmm oil and shrapnel lol


There it is...

Motor out

Ziptie, transmission holding, apparatus (very technical)


The blown motor...
 

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Discussion Starter · #3 ·
Lower runners out, cylinder 2 had the BB sized metal in em. Literally looked like it was melted, shaped into a Wonka Nerd candy, and solidified...

Death hole

New block to be bored and honed .20mm over (let's hope round 2 goes well)


Misc. parts



Crank from the new bottom end that is going to the machine shop...some shotty work has been done to this in the past...notice how it's been shaved unevenly, or shaved on one side and not shaved on the other...Gonna see if we can get it knife edged, at the very least evenly shaved...




 

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Why not just pull the trans with the engine? It's like 8 bolts and a hydraulic line. Easier to remove and install from outside the car IMO. Looks good though! Looks like it should be a fun car!
 

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Discussion Starter · #8 ·
Thanks guys, yeah I want to do that initially and pull the trans out with it, but it wasn't too bad getting it out this way as well. If all goes well she'll be up and running by this coming Monday. Once that's done ill be saving up for the rest of the turbo parts while I break in the motor. All I need now is new intercooler piping, new intercooler, new oil lines and fittings, and big 4.25" oval pipe for a new custom exhaust were gonna weld up. I'll be looking forward to that massive exhaust lol. And also I'll be purchasing an AEM meth kit and mas gauges. The list goes on...lol for now I'm just trying to get the car running and trouble-shot. Goal is to be 100% done with motor, turbo and tune by TX2K12. Stay tuned for more updates.
 

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Discussion Starter · #11 ·
Should have more pictures up, and a start up video by Monday (hopefully).

Irish_Supra, I was the one who added you on FB the other day ;) Let us know how that new manifold turns out.
 

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Discussion Starter · #13 ·
Update!

Ze blown motor


Bottom looks good though


Cylinder 1

Cylinder 2 (my favorite)

Cylinder 3

Cylinder 4

Cylinder 5

Cylinder 6


Note, every piston was shot except cylinder 1 piston...damage ranged from small abrasions, to complete chaos (cylinder 2 :))
 

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Discussion Starter · #14 ·
Ze progress

Painted everything black




As the car sits, the motor and trans are in. Fluids are in. Entire wire harness and misc harnesses have been plugged into the matching plugs. All vacuum lines have been routed. Timing has been set (again :pissed: ) Just to let you all know routing the wire harness and vacuum lines suck balls. Adjusting timing so it's PERFECT is even worse! But all there is to do is double check every bolt, nut, plug, hose and start her up! So excited :) I've been without a car for well over 2 months now.

AND! Some new turbo stuffs came to my doorstep as I was working on the IS at Kam's house :)

(yes it's a Gen2)

 

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Man either I've been missing this in my is or club lexus but you need a hug!! Lookin good brother
 
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