Realistically, how hard is the KA24DE to rebuild?

[Xektrez]

I don't have a 240 yet, but I'm trying to find a hatch to daily drive for a while and also build another KA24DE for it separately on the side as my project. I have literally zero experience in any of this, so I feel like it should be this complicated and very tedious process. But, I've been looking around A LOT on different threads and tutorials and such, and it just doesn't look very hard. I'm not a corner-cutter, so I pay attention to the details such as what exact torque everything should be and stuff.

I plan on rebuilding it while looking at a guide. I found this: http://www.ka-t.org/forums/viewtopic.php?t=4156. It looks like a pretty good write-up. The hardest part looks like holding the pulley while putting on the front plates. Also the timing confuses me a bit. Do you guys think this looks good? Is there anything I should know when I do the rebuild? I'm probably going to buy a full rebuild kit, any good ones that you guys know of?

About the timing chain, I know it has the discolored loops from the rest of the chain. When I go to replace the chain, should I make marks exactly where I took it off, and put it exactly back on that way? The timing part is still a little bit confusing, I haven't looked into it a whole lot and tutorials on engine rebuilding don't really go in-depth on the subject. I'll probably look something up once I post this actually lol.

But anyways, if you pay attention to the details and go slow, is it really that hard? I just feel like I understand it more than I should, because I've never done, but it makes sense to me. Idk, I guess I feel a little intimidated by the fact I'm taking an engine apart and it's up to me to rebuild it correctly, I don't want anything to be loose or not correct once I put it together.

[PapaSmurf2k3]

You can certainly give it a shot and come back if you get stuck anywhere. Just try not to drop stuff and damage it. Deciding if you want to bore the engine out (and get new pistons) is another thing you'll have to do.

[Xektrez]

You can certainly give it a shot and come back if you get stuck anywhere. Just try not to drop stuff and damage it. Deciding if you want to bore the engine out (and get new pistons) is another thing you'll have to do.

I've thought about sending it to get bored and honed, is it worth it? Also, what are some key signs to see if the block/head is bad? Like are there any common crack areas? I plan on replacing everything unless it looks like it's on it's last leg.

[PapaSmurf2k3]

Nope, nothing is really fundamentally wrong at the core. Machinists will check the bores to see if they are starting to become oblong, or if there's a shelf in them, etc. They can check the head to see if its warped, and also adjust valve lash (although you can also do that).

[Xektrez]

Nope, nothing is really fundamentally wrong at the core. Machinists will check the bores to see if they are starting to become oblong, or if there's a shelf in them, etc. They can check the head to see if its warped, and also adjust valve lash (although you can also do that).

So are you saying getting it bored isn't worth it, or that the block usually doesn't get messed up? I might plan on putting a turbo on it later, once I learn a little more about modifications and engine work. I'd do lower boost tho, because I would still daily it, so is it worth boring for that.

[PapaSmurf2k3]

I'm saying I'm not there with your naked block to make that call. You should bring it to a machinist and see what he says.

Boring wont really help you with going turbo. Adding forged pistons and changing your compression ratio will.