Original and the replacement.
Fuel tank hardline adapter
TIL that the hardline coming from fuel tank has a 60 degree cone at the end and the thread is BSP(P) 1/4″ -19.
It should be fairly easy to find/make a adapter to change it to whatever.
Nice 🙂 it gets easier to build the ethanol compatible fuel system.
Piston rings
Piston rings had me stalled for a while. For some reason it took me quite a long time to get started to file the ring end gap just right.
Rings installed:
Found this tool in Widrics stash. Worked wonderfully.
Below: top ring, polished (chrome?) outer side, slightly barrel shaped.
Non- and critical things missing (Part 7)
Edit 1 – 22.8. Fuel line adapter and hose made
Critical things missing – copied from earlier post
- Cam followers (1SZ-FE solids. Currently measuring clearances)
- Wiring loom (the stock wiring of the maxxecu is very long – not sure if anything serious needs to be done)
- Intercooler (Ordered a custom A2W from Plazmaman)
- Oil filter relocation hoses and misc bits
- Oil filter relocation take off plate
- Oil filter relocation other end
- TPS sensor (Possibly toyota stock)
- TPS sensor connector (Whatever toyota stock uses)
- Radium fuel pressure damper (E85 compatible)
- Radium fuel pressure regulator (E85 compatible)
- Fuel pressure gauge (Radium?)
- Adapter for Pivot fuel pressure dash gauge
- Fuel system hoses, ethanol compatible (DIY, professionally crimped?)
- Fuel system bits and misc
- Turbo oil line and drain
- Turbo coolant line and drain
Non-critical things missing
- CAN Bus wires for the ecu (found something interesting for this)
- New plugs (maybe, I got iridiums both on my current and spare engine)
- Clutch plate (maybe, no idea about the current condition)
- Fuel system (hoses, etc.) ethanol compatible
- Cam gears (maybe later and maybe toda. HKS Camshafts work with stock ones)
- Rear motor mount + damping?
- Shift lever bushing? (what was this?)
- Titanium axle bolts 🙂
- Silicone coolant hose kit
- Engine bay coolant bleeder screw
- Flex fuel sensor (when the time comes)
- Hydraulic throwout bearing (MRP)
Stuff that needs to be done
- Cleaning block (in progress)
Done list
- Intake + throttle body
- Plan A – custom intake is being made (Waiting)
- Plan B – Techno Toy Tuning adapter ordered for smallport intake (Done!)
- Trigger wheel
- Plan A – ordered from Techno Toy Tuning (Done!)
- Plan B – next door Toyota guy makes one (Waiting still but yeah)
- New pulleys (ordered from TTT, arrived, done!)
- Coatings for pistons, turbo and exhaust manifold (Done!)
- Cleaning cylinder head (Done! Found out that Aluminum boat cleaner works well (Oxalic acid))
- Injectors + connectors (Done! EV14 714cc with ethanol compability)
- Ethanol compatible fuel pump (Done! AEM)
- Cam covers (Done! But doing then better this time)
- Crank bearings (Done! Friction reducing coating)
- Conrod bearings (Done! Friction reducing coating)
- Exhaust and downpipe (Done!)
- Head gasket (Done, Cometic)
- New pistons (Done, Matrix Garage/Arias/Traum pistons)
- Gear shifter that small bearing that is at the side of the shifter (Done! Matrix Garage)
- Gear shifter bearings (Done! Matrix Garage)
- Shift base bushings (Done! Matrix Garage)
- 2-component silver paint for the epoxy painted parts (Done, tried new type of 2K paint)
- Fuel pressure regulator (Done, found the missing parts 😀 )
- Crank wheel/harmonic balancer (Done, I found a aluminium one from my stash)
- Rear tie rods (Done, Matrix Garage + installed)
- CLT sensor (Done! Bought a stock Toyota one. Thread is M12 x 1.5 – maxxecu suggest using a bosch CLT)
- New rear bearings (ordered 7.7.2018)
- Crank angle sensor bracket (D4A, 9.7.2018)
- IAT sensor
- IAT sensor connector
- CLT sensor connector
- Crank angle sensor
- Crank angle sensor connector (well, technically no)
- That special little adapter which goes to the fuel tank hardline end (working on this, ordered a stock fuel line to check this) – It’s BSP(P) 1/4″ -19
Uncertain
- Idle air valve (uncertain)
- Turbo hardware kit (uncertain)
- Aluminium radiator
- Knock sensor system (plex or that other one…)
- Engine oil cooler (laminova or something else)
Techno Toy Tuning pulleys, trigger wheel and bigport adapter
These arrived recently. I have to push forward the rest of the build now 😀
Matrix Garage rear tie rods
The hardest part was to remove the old stock rear tie rods
Why didnt Toyota originally do the rear tie rods like this??
Really easy to adjust 🙂
Non- and critical things missing (Part 6)
edit 1 – 3.7.2018 – added hydraulic throwout bearing
edit 2 – 4.7.2018 – added fuel pressure regulator and damper
edit 3 – 7.7.2018 – moved fuel pressure regulator and damper to critical things – realized that if I’m ever going to make ethanol compability to happen, I need to rebuild whole fuel system. Stock damper is totally out of question, it is made for a stable 2.5bar pressure and the AEM pressure regulator that I have, is not confirmed for E85. (Neither is the stock damper)
Also, made the critical things list bit more detailed if there is need to order stuff from multiple manufacturers
edit 3.1 – 7.7.2018 ordered following parts:
- iat sensor (M12) + bung (aluminum) + connector
- clt terminal
- can bus wires
- generic crank position sensor
Critical things missing – copied from earlier post
- Cam followers (1SZ-FE solids. Currently measuring clearances)
- Wiring loom (the stock wiring of the maxxecu is very long – not sure if anything serious needs to be done)
- Intercooler (stock one wont do. Must order that A2W (AVT Chargecoolers?) A subaru one? A celica one?)
- Oil filter relocation hoses and misc bits
- Oil filter relocation take off plate
- Oil filter relocation other end
- IAT sensor
- IAT sensor connector
- CLT sensor connector
- TPS sensor (Possibly toyota stock)
- TPS sensor connector (Whatever toyota stock uses)
- Crank angle sensor
- Crank angle sensor connector
- Crank angle sensor bracket (D4A, 9.7.2018)
- Radium fuel pressure damper (E85 compatible)
- Radium fuel pressure regulator (E85 compatible)
- Fuel pressure gauge (Radium?)
- Adapter for Pivot fuel pressure dash gauge
- Fuel system hoses, ethanol compatible (DIY, professionally crimped?)
- Fuel system bits and misc
- That special little adapter which goes to the fuel tank hardline end
- Turbo oil line and drain
- Turbo coolant line and drain
Non-critical things missing
- CAN Bus wires for the ecu (found something interesting for this)
- New plugs (maybe, I got iridiums both on my current and spare engine)
- Clutch plate (maybe, no idea about the current condition)
- Fuel system (hoses, etc.) ethanol compatible
- Cam gears (maybe later and maybe toda. HKS Camshafts work with stock ones)
- Rear motor mount + damping?
- Shift lever bushing? (what was this?)
- Titanium axle bolts 🙂
- Silicone coolant hose kit
- Engine bay coolant bleeder screw
- Flex fuel sensor (when the time comes)
- Hydraulic throwout bearing (MRP)
Stuff that needs to be done
- Cleaning block (in progress)
Done list
- Intake + throttle body
- Plan A – custom intake is being made (Waiting)
- Plan B – Techno Toy Tuning adapter ordered for smallport intake (Done!)
- Trigger wheel
- Plan A – ordered from Techno Toy Tuning (Done!)
- Plan B – next door Toyota guy makes one (Waiting still but yeah)
- New pulleys (ordered from TTT, arrived, done!)
- Coatings for pistons, turbo and exhaust manifold (Done!)
- Cleaning cylinder head (Done! Found out that Aluminum boat cleaner works well (Oxalic acid))
- Injectors + connectors (Done! EV14 714cc with ethanol compability)
- Ethanol compatible fuel pump (Done! AEM)
- Cam covers (Done! But doing then better this time)
- Crank bearings (Done! Friction reducing coating)
- Conrod bearings (Done! Friction reducing coating)
- Exhaust and downpipe (Done!)
- Head gasket (Done, Cometic)
- New pistons (Done, Matrix Garage/Arias/Traum pistons)
- Gear shifter that small bearing that is at the side of the shifter (Done! Matrix Garage)
- Gear shifter bearings (Done! Matrix Garage)
- Shift base bushings (Done! Matrix Garage)
- 2-component silver paint for the epoxy painted parts (Done, tried new type of 2K paint)
- Fuel pressure regulator (Done, found the missing parts 😀 )
- Crank wheel/harmonic balancer (Done, I found a aluminium one from my stash)
- Rear tie rods (Done, Matrix Garage + installed)
- CLT sensor (Done! Bought a stock Toyota one. Thread is M12 x 1.5 – maxxecu suggest using a bosch CLT)
- New rear bearings (ordered 7.7.2018)
Uncertain
- Idle air valve (uncertain)
- Turbo hardware kit (uncertain)
- Aluminium radiator
- Knock sensor system (plex or that other one…)
- Engine oil cooler
Welding a exhaust adapter together
Having a bit of free time in our hands, we built a adapter for the new turbo exhaust so it could be fitted to the stock 4AGZE downpipe. I was mostly in the way while Mr. Reynolds welded and cut pieces of pipe. Also, I pointed some things that shouldnt be welded.
We removed the old exhaust from the car. It was very heavy, felt like it was made from cast black iron.
Old one on the left, new one with a small downpipe adapter. Please notice the white protective wrapping around the silencer. We forgot it and it burned.
Mr. Reynolds had to take a break and while he was away, I prepared the old downpipe for cutting and welding.
While removing the downpipe heat shield, I found some white insulation mat between the halves.
Went and grabbed some breathing protection for separating the halves and cleaning. At the end, no idea what this was, but I had to treat it as asbestos and be extremely cautious.
Mr. Reynolds separating small bright flying dots from the adapter
Welding
Welding
and welding
Finally:
Well done!
Couple of days later I took the whole exhaust down again to get rid of that burnt protective plastic.
And this is how it looks. Very shiny. Also, this picture already show the brand new Matrix Garage rear tie rods installed:
The noise is… well… not biblical. No horns of jericho this time, more like a single trumpete(e)r in the night with big lungs and lots of passion. 😀
Video comes soon.
Technical coatings for parts
The new pistons came from coatings. Piston has now heat resistant top coating (there is something very pornographic to have golden pistons), friction reducing coating on the sides and the underside has been coated with heat transmissive coating.
The exhaust manifold and the turbine housing have been coated with stuff that keeps the heat inside. I chose blue color for some reason, thought it was cool and only afterwards heard that it changes color when heated. I cant wait to see that in person 😀
Other color choices were black, different shades of grey and red. In the photo below, the color seems bit intense.
Edit: this is how the piston was prior coating – all the sharp edges rounded
