Jims '93 Alltrac Build Thread, start up vid PG7! Options

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As promised, jimbo, heres the build thread for the 'trac.
ill let you fill in the story of how you aquired it, ect, im just gonna post pics and info as i go about doing the work for ya.

so, lets get this show on the road!

first, jim came up friday with a '93 alltrac, that had a blown motor with no head on it, attached to the AWD tranny, hanging in the bay by only the drivers side mount.
in the back of his truck was a 3rd gen 3s setup, WRC tranny, and some random parts for the swap.

we got the car in the garage, and once i got the hood off and stared in amazement for a few moments, i started getting ready to litterally drop the motor out the bottom.
the crossmember and stuff was already out, all i had to do was remove the shifter cables, clutch line, and speedo gear.
i took out the 3 bolts holding the tranny bracket to the mount, and out it came with a thud.
joe gave me a hand pulling it out from underneath, we hung out for awhile, and that was that for friday night.
saturday morning, we went out and pulled the motor and stuff off the back of the truck, and got it into the garage.
the motor had parts of a TD06 turbo kit on it, and jim and i walked thru how he wanted it setup, and off they went.
today, i went out and got to work.
sorry for the blurry pics, for some reason my camara dont like to take pics under the floresent lights.

the bad 2nd gen and tranny



engine bay



the new motor (i had already clocked the turbo closer to where it will be in these pics)





minor clearance issue



whats wrong with this pic?



hrmm..a little gasket maker?



clearance issue solved, so lets make a screamer pipe!!

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i've never seen a swap that tweak did the harness on that had issues. since this is a 205 into a alltrac, the wiring is more complicated than a 205 swap in a 6th gen, which is MUCH easier.
DG, and mikes were a diffrent story.
tweak does excellent work, he just did a bodyharness for my cousins mr2 project and it was 100% plug and play perfect.
anyway..
the progress for today...
got ready to install the cam gears and timing belt, we recently tried this new "gel" threadlock from permatex. this is the threadlocker i will buy from now on, its absolutly the bomb.
the liquid stuff tends to be runny, hard to tell if there is enough on there, ect.
this stuff being a gel sticks on the bolts, and dont run off, less waste, and works great. i like the blue, cause it holds everything together well enough, but dont permanantly lock things together.



i had to retap the lower tensioner bolt hole, you can see the damaged threads in this pic



somthing odd about this particular motor. every 3s ive ever seen has notches on the back of the cam caps, and cams, to line them up for timing.
this motor does not have them.



cam gears and t-belt installed



im also going to be installing an adjustable fuel pressure regulator, so i took a pic as i was removing the stock FPR.



we are going to run it in a "deadhead" setup, where the stock return line is eliminated, by using the return on the areomotive FPR.
in a stock setup, the fuel runs like this:
pump - filter - rail - regulator - return
the new configuration will go
pump - filter - regulator - rail, with the return coming out of the regulator.
the main reason to do it that way for me is just ease of install, and its proven to work just as well if not better than the stock setup, also there are less fittings and line this way which makes it cheaper.
more to come, tommorow we pull the fuel tank!