Turbocharging Saga....Part 2

Ok, so this project has had its share of set backs...as told in my Headwork thread. So hopefully Ill get my head back the first part of the week so I yet again measure some clearances and get my buckets ordered.

In the meantime I started working on the bottom end today. So Id thought I share some things. For those of you that ever decide to rebuild a GTE motor there are lots of things you need to do but there are two very important things that need to get cleaned on the block. The Oil galley that runs along the block and the oil squirters.

Here is a look down the galley with the plugs removed. As you can see, you can see right through the motor.




View from the rear.




This is the turbo oil feed, that is fed from the galley shown in the previous pics.





Here is the new plug installed. You can reuse the old ones or pickup new ones for roughly 4 bucks a each at the toyo dealer. They have what appears to be green loctite on them, so if you reuse them youll need to put a thread locker on them.


And these are the cylinder squirters, sorry I didnt take a picture of them out or me cleaning them.


I cant stress enough on how important it is that if you are rebuilding a motor to pull the squirters and the plugs from this oil galley out. I remember before I sent my motor out i pulled out the plugs and this galley was caked full of gunk.Without pulling the plugs, even in a hot tank I doubt that all the crap would have came out. This would be a disaster waiting to happen. Especially since this the feed for the turbo.

 

I also discovered that when you go to ARP studs, that even the aftermarket Cometic Oil pan gaskets required trimming to clear the main cap studs.



And here is my progress for today.
Starting to look like a motor.



I also have to give some props to my wife as she spent a few hours with a right angle air tool with some scotch brite wheels and a wire wheel cleaning my intake.


I also spent an hour or two at the parts cleaning tub washing down the oil system for the turbo. Ill post some pics tomorrow once I finish it up. Cleaning out the factory oil cooler setup is a real PITA!

 

:driving When she isnt keeping our kids corralled she wants be out helping with the car. With as much that needs done, Ill take all the help especially on the not so great jobs.

 

Yeah, I was reading that the GE intakes flow better. But this will have to do for now. Got my head back today and need to finish up my calculations tonight, then tomorrow go up to the dealer and order my shimless buckets.

 

Well, Ive been saying since I did it, that someday I would take a part my gauge cluster and show how I built. Well today I had to yank it out to add my oil temp gauge so here are some pics.

The panel that all the gauges are mounted to is a painted black piece of aluminum that I got from some electronics equipment(my workplace).

Here is the back. Completely custom made harness.



I cut off all the factory plugs from the car harness and wired in new plugs two different size "Molex" style connectors.



The whole assembly is is mounted to the plastic cluster bezel in several different places. I had to trim this plastic several times to get the right angle to mount the aluminum panel on.



Here is a close up of some of the idiot lights and the open spot where Ill be putting the new gauge.



New hole for the oil temp gauge.



And here is the cluster with the new gauge put in.




I also swapped out my standard A/F gauge for my new wideband A/F one.

 

1FSTGTS's Turbocharging Saga

So ventured out to the garage today.

Since Im going Haltech standalone ECU, my stock harness is not gonna work out so well. However, Im going to need some of it to still make the girl go.
Harness hacking is not exactly for the faint at heart.

So here are my two harnesses, the top is the GEN2 GTE harness, and the bottom one is my stock GEN1 GE harness from the car. I already had cleaned off the GEN2 one but now its destined to just be a donor for wire and connectors.


Heres the pile of stuff removed from the GEN1 harness. Tedious work with a razor not to nick any wires. That would be a gremlin that I just dont need.



So after its all said and done I have the harness separated out to the parts Ill need to reuse to the ones I wont.


Alternator/charge portion of the harness


Various other sections including Injectors, Cruise and AFM which wont be getting reused, only just for wire. Im not sure how long the wire is going to be on the new ECU so I may have to extend some of them.




And yet another section of the harness separated out.


And yes several bottles of the thing on the bottom were consumed during this process.:naughty

 

This is right up my alley because I work with electronics and wiring for work and I enjoy it. But this is certainly gonna be a challenge. Labeling and documentation will be key. Im gonna keep as much of the factory color code as possible.

 

I have a label maker(courtesy of work) that prints labels on nylon tape.(We use it to label cables and wires). That Im gonna label each plug with...kind of over kill but hey Ive got it so Im gonna use it.

http://www.bradyid.com/bradyid/pfpv...table-Label-Printers~BMP21-Label-Printer.html

 

:lol2 Yeah sure...its not the label maker that kills you in prices its the tapes that are 20 bucks a crack. But again, my work conveniently replaces my tapes for me. I usually order them 6 at a time since I use so many of them for work.

 

:rant

So my build is as at somewhat of a stand still..stopped at the Toyo dealer yesterday and my shimless buckets are on backorder for a little while longer. My ECU has been on backorder... Grr I cant do much else with my motor until I finish the top end.

May try and do a little bit of odds and ends tonight...just frustrating when waiting on parts.

 

Yay! Finally after two weeks my shimless buckets came in from the Toyo dealer. Now I can assemble my head tomorrow.

 

So yes..Shimless buckets are a PITA!
Im glad I order a few extras of different sizes because, well I ended up needed them. Not sure why, I made measurements and put them all in a spreadsheet and then had excel do all the calculations. :study But when your dealing with a difference in the thickness of a sheet of paper the slight mis-measurement will eff it all up. I only had my cams and caps off and on my head at least 4 times tonight to get all the clearances right.

Anyways, finally all done. :thumbsup:

Now I can start getting the last parts of the motor together. I just need to finish cleaning up the intake and valve cover.





For whatever its worth, heres what a Shimless Toyota Bucket looks like. They mark the sizes( the last 2 digits of the total size) on the inside of the bucket.

 

No pics, but been busy cleaning and polishing. Got the Gen2 GTE valve cover cleaned up and starting to polish it out. Still need to tidy up the intake manifold. Working on Cleaning the TVIS. Lastly, I need to clean up the throttle body, which is in pretty rough shape. Im hoping to have my ECU and stuff sometime next week.

Now I just need to decide what the hell Im doing for a tranny. Ive got my S53 partially tore down and need to get it all the way apart to see what gives with the 2nd gear. Im having a hell of a time finding a Solara tranny locally. Best price so far was something like $950 shipped in.