99 AE101 BZ Touring 3sgte Build Thread

hey guys so this is the begining of my build thread, i started the build roughly 2 months ago but also just finished rebuilding a 5afte ae101 levin so have been able to spend a lot of time on it but as i now have time i thought i shall start this thread.

firstly about myself, no one here may know me but my name is kieran, im a sparky and come from new zealand, im writing this up for other people to follow and learn from my mistakes but also as a record of my own.

from the start, 2 months ago i decide that i was going to do it, 99 bz touring wagon with the 6 speed 4age blacktop came out and was put into another wagon, motor was on its way out only showing 115 compression all around so no better time right? heres a few pics before and taking the motor out










after this point was a bit of a clean up but thats about it, shes since been parked up awaiting the next move

since then i have bought an mr2 with a good gen 2 3sgte motor and the rare e153 lsd box and pulled the motor, stripped it and now thats awaiting an overhaul, thats where i am now currently and will start building that motor up soon

Nice work so far

thanks mate, just been so busy lately, looks like ill finally be able to put some good hours into this, buying a full rebuld/overhaul kit from toyota in the next coming weeks and will get the motor all freshened up

Can't wait to see more

Looks really clean!

So I've started to buy some parts now, got a full gasket kit, some ignition parts and a lightened flywheel, also bought myself another levin so doing a bit of work on that in between but next step is to clean the motor up, paint the block black and install all these gaskets.

Spent a bit of time on the motor today, taken the head off to inspect the motor further, pistons are good, cylinders look good also, no lip or deep scratching. scraped all The old head gasket off and have done some deck clearances, all warpage is within the specs so happy as. I have cleaned and painted the block black. I think I'll tackle the head next, need to clean that up and get it machined.

Continuing on from the block, I've pulled the frost plugs out ready for The new ones to go in once I get them, painted the sump also. Jumped onto the head and took it to an engine builder I know to machine the head flat, have since pulled all the valves out and done the stem seals, cleaned the valves and put them in again,m. Unfortunatly I haven't had the resources recently to lap the valves so have decided to give that a miss for now, I know I should really do it but I'm prepared to take the motor apart in the future anyway so of it becomes an issue I'll just have to go back to it. Anyway valves are all back in and cleaned up after some time getting the bloody shims back in to hold the valves. Head is now back on the block with the new multilayer metal head gasket, still waiting on some new headbolts so can't torque it up just yet but luckily unlike 4ages you can put the cams back in without needing the head bolts underneath them. Did The camshaft seals and now they are in but again not torqued up just handtight, got a couple things to do before I get them down. Would like to add that I am oiling up all moving parts on their contact areas  just in case anyone was wondering.

great work so far

Did plenty of work over the weekend, frost plugs are in, used a bit of high temp rtv on the outside of it and to punch them in I used a washer and socket, didn't  any to damage them and mark them haha. Finally got the head bolts so I put them in and torqued them then torqued the cams down also with new cam seals etc and ofcourse oiling all the bearing caps etc etc. next biggest issue was waiting on an oil pump, once I got that I could put it in and get the oil pickup, little baffle plate and the sump bolted on, then I got the water pump on and all the new seals etc, also the timing belt kit went on with the new pulleys and cam belt. I did get a new tensioner but it was for the gen 3 so was slightly bigger and didn't fit, so I did the test according to the manual to see if mine was good and yes it was fine so it went on.
Here's some pics of current state.

Big Breakthrough with my axles!! After lots of research and mixing and matching parts I had a few ideas, but went off to my parts store and gave them a few measurements, I am using the e153 turbo box and wanted to keep my hubs stock if possible because it would be easier for certification, now issue is that the e153 axles have a bigger diameter then c160 axles so my cv won't go on, a lot of forums talk about using camry axles etc etc etc. I took the outside diameter of the axle which is 79.3 mm, it has 27 splines, the ae101 hub has 26 splines, so with those measurements they could find something on the system that matches, a cv with inner spline of 27 at 80mm to fit the axle and outside spline of 26 to fit the ae101 hub. They came back with st185 celica gt4 cvs, with a test fit its a perfect match! Also the axles are the right length. Aside from that I now have a clutch and some new wheel bearings, factory ae101 gearbox mount fits so just a few more to sort out.

Motor is now mounted with 3 mounts, one to go, also how found that the c series selectors work with this  e series box so have bolted that up, making progress and things are starting to take shape, -also have painted the gearbox and she looks good.

Awesome progress mate! Nice to see another member from NZ! Where ya based? I'm in Wellington

Haha cheers man, I'm based in Auckland

Hey guys, long time since I lasted updated this and have been extremely busy on the old girl, has since done ALOT on this project, since finished painting it all, installed everything, decided to go for somthing a hot different and so a water to air intercooler, put an oil cooler in and put 3 gauges in, used my original alloy radiator and welded the bottom pipe to the drivers side of the car to suit the motor aswell as a nipple for the turbo water Line to go straight in. Had to cut and weld a shifter arm so it goes into all gears nicely, had plenty! Of issues with the starter motor and starting it when trying to get it going for the first time, was pretty big feat though to have her idling and now have the intercooler all hooked up and is making boost, here’s a few photos of all the progress so far, not much left to do now. Cheers to all who have followed this project and I hope I have inspired others to get dirty with the mighty corolla

Nice job!!

That is AMAZING! My dream build! I went with the 2ZZ because i could not do the 3SGTE..
Is that 4WD now? Because 3sgte are rear or 4WD and that would require significant frame work and i just could not do that

shah.saib.7 wrote:

Because 3sgte are rear or 4WD

3SGTEs are only rear-wheel drive because they are mid-mounted in the MR2. They are still a transverse "FWD-style" layout.

Yea so essentially it’s an mr2 just moved everything to the front so it sits over the front axles and not the rear like an mr2, here’s a few more pics of the car now it’s done

Love this build, you've still got this right?

Sent from Topic'it App

Hi... wondering if you have any source for ae101g (bz touring) option parts like

1. net cover after the backseat
2. Toyota power outlet in the rear boot (DC12v/AC100 outlet) it was an optional part

Such a cool build, love how anal some can get by painting everything making it like new, the time I will never have I recon. Awesome build