Markstevieandmads Budget Turbo project : PART ONE

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markstevieandmads
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Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

androo007 wrote:Hurry up :lol:


Easier said than done with 3 kids,a full time job plus overtime plus callout and trying to keep an eye out for my grand parents.

Just chipping away at it. Just ordered the last gasket i need for the downpipe to flexi and i think i may have the last bits needed.
androo007
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Re: Markstevieandmads Budget Turbo project : PART ONE

Post by androo007 »

I'm only joking pal, keep it up its so close!!
markstevieandmads
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Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

Feels like one step forward and two steps back.


Having trouble getting the core all lined up as existing pipework is in the way so gonna have to have a think...
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

LITTLE UPDATE:

Got an hour on it today before dinner so got the new temperature sensor installed.

Also got the relay mounted and the wiring ran and connected on to the relay and fuse box area.
I used a multimeter to determine the thickest cable going into the fuse box that was a switched live (black with red stripe) and connected the main battery terminal in the fuse box to the relay through a fused connection (25amp). Wiring is rated to 30amp and the relay is 30amp too.

I wanted to mount the relay somewhere using an existing bolt and didnt want to drill a new hole in the bodywork so used a bolt beneath the coolant filler.
Probably not the best place, but it was close to the fusebox and the relay is turned around and sealed so shouldnt get wet.

Image

I used an existing earth point for the earth to the relay. I used heat shrink,solder and isolation tape and also made a small hole where the lid sits to run the cables and keep the fuse box dry.

I didnt have enough room to jack up the rear and get underneath to solder the pump wiring as i couldnt get the car out the garage due to rain.

I also continued trying to get the core aligned up. I think with a bit of persuasion it will come. Ive got the throttle body sock stuffed into another boost hose and clamped together which i am not too happy about but will have to do for now until i come up with something else. It maybe worth keeping an eye out for a st185 core as these fit better.
For now, i think the st205 core pipework will need a bit of trimming and gentle tapping with a mallet to get it to align better.

So, a few more things ticked off the sheet...
markstevieandmads
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Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

MORE UPDATES:

Lovely weather again (for a bit) so pulled her out again and carried on.
Firstly new plugs...
Image


I used densos on the last service and the car ran well with them so replaced them like for like.

Image
A pic in case anybody doesnt know where the spark plugs go lol


The old plugs in the same order i took them out for each cylinder. Do they look ok?

Image


I jacked the car up and wired the pump up with the earth going to the pump mounting bolt and the positive going to the relay.
I then put the battery back on and put the igntion on expecting to hear the pump and nothing - removed the fuse and that was ok then broke down the circuits checking what was happening. Checked the relay was clicking over on ignition which it was. Then checked the earths and all good. Then checked the power at the pump and there was none - doh! left the fuse out! So put the fuse back in and had 9v at the pump. Checked the battery and the voltage was dropping real quick...Damn...the battery is knackered. Ive stuck it on the charger but i may just get it exchanged if i can find the receipt as it is under 3 yr warranty and not long ago charged it up and never even used it after i did.

Next, I managed to mount the standard bov with some spare hoses and extended some other hoses to fit. Also trimmed some of the pipework for a better fit.

So now i am all done except i cant get the turbo hose lined up. I keep trimming the core hoses but its still about an inch out.Ive managed to get the throttle body lined up but then its out on the turbo.

Im still not happy bout clamping a hose on top of the throttle body sock as i am sure this isnt going to be a great seal.

Image

So i got the bro in law (to the rescue!) coming round again at the weekend and hopefully between us we can get it all lined up with the bits of boost hoses we have left.

Then once thats all mounted its just new oil and coolant refill and bleed and we should be go!

Heres how i left it...


Image
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

YET ANOTHER UPDATE:

Had a big incentive today to get the car finished as me and the bro in law had a drift day.
On the way back we fancied popping into forge motorsport and on the spur of the moment (and a nice discount for cash) i bought a nice shiny twin piston bov for my car....ok its a rev 2 so i may suffer a bit with the afm but i am planning on going rev 3 conversion at some point so will keep it if it affects it too much.

Anyway, got it installed.

Image

I nice touch i thought was to block the original hole in the afm hose with a 7up cap and clamp lol


Anyway, i didnt like the way the boost hose clamped on to the rubber of the st185 throttle sock so after reading that some people actually managed to get the sock to fit the st205 core direct we got the kettle out and after a few goes we got the st185 sock on to the core with a clamp.

Image

With the sock on properly, the core aligned with the turbo a lot better and we was all clamped up and all hoses installed!

From the pic above you can see a d.i.y solution to the throttle cable bracket.

I had bought a 2nd hand st185 throttle cable bracket from tcbparts but just couldnt see how this fit. It didnt look like any other pic i found of a st205 core on to a rev 2. I believe it may actually be a st205 bracket ive been sent. So we got inventive and made our own bracket for the throttle cable which works well.

So everything is now installed.

Image

Image

Still awaiting my sump plug washer from toyota so i can drain and replace the oil.
I also need to fill and bleed the coolant for the engine and charge cooler system.
And i need to find my support bracket for my decat that i bought ages ago but cant find (grrrrrrrrr). Just need to find or make another and then connect the decat to the exhaust backbox as soon as my gasket arrives for this.

Then a test drive (on private road obviously) and then put the under trays back on and mot.

I also want to fit a temp gauge for the chargecooler that i got and also source (when money allows) a afr gauge and need to put a bolt to block the sensor place in the decat.

Not far to go now!
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

DEPRESSING UPDATE :(

I was so close so continued.... i ripped the garage apart to find the decat bracket i purchased from a member about a year ago but did find it

Image

so installed this along with a nice new decat gasket and a bit of paste. The bracket to the block just didnt want to sit where i wanted it but managed to bolt it to another bracket down there which is nice and solid.


Image


As i was waiting for the oil to drain i started fitting the other bits and pieces back in such as the strut braces and the engine lid.

Image


With coolant filled in both the engine and the chargecooler and the new 10w 40 oil installed (magnetic sump plug showed no metal fillings and new sump washer fitted) i decided to give it a go starting. I have a nice hole in the decat where a afr sensor should fit which i havent got but thought it shouldnt make much difference. So i pulled the efi fuse and the king lead and with a fully charged battery i cranked it over a few times.
Then with trepidation i plugged them all in and with the turn of a key the car burst into life after a good 4-5 months off the road. It felt like bliss!!!

I have got a vid of the startup. Excuse the shiny bald head,baggy pants and moobs....my car clothes..

https://youtu.be/YoAy1JbqeLM

Anyway, my bliss was soon cut short....

The car was idling fine and the temp was coming up nicely to half way. I kept checking the coolant in both engine and chargecooler and there was no leaks so all good so far...

However i had a few lights on my dash...

Image

Ive got a engine light on the rhs which im sure is the intercooler fan. This is unplugged so im hoping plugging that back in when i install the fan in either the lid or the original position for a bit of extra cooling will clear this. If i dont do that then i read if i get rid of the fan ecu and relay the light will go out anyway so not a biggy.

Ive also got a PS light and the power steering isnt working. Now, i had the occassional problem with this previously but ignition on and off cleared it. However doing this a good 30 times and its still there. It clears first of all when starting but after a few seconds it comes back. Im gonna give the relay a whack with a spanner for now and check the fluid later but if not then i do have a manual rack and steering column to fit but that means more work and will need a good alignment afterwards....need to get this sorted either way before mot.

Fog light isnt working. I knew about this. When i removed the interior trim for something the wires came out the back of the aftermarket switch. They were fitted to part of the original loom with male spade connectors and i plugged them back in but obviously not in the right place as the fog tell tale light just stayed on and the rear fog lights didnt work. I just disconnected it for now so that needs sorting for mot.

Now the major problem....

I have a major blow on the exhaust. I know there would be a blow from the lambda sensor hole and i have a bung ordered for this as couldnt find anything local to fit it for now so that should be here tuesday.
However, it sounds like it is blowing up top too. All new gaskets was used so the only thing i can think is its blowing from the exhaust manifold area. I tried putting my fat fingers around various places but obviously it was getting hot plus the core,heat shields etc was in the way.

So i ended the day in a real depressed mood. It looks like the core and heat shields will need to all come out again which means all the fluid from the chargecooler core and pipes will need to be drained again and trying to get them all aligned again is a major task. I then have to try and find this blow which im guessing is the exhaust manifold so again and possibly more things need to be removed.
I did have the idea of putting on the original greddy copy intercooler while im chasing this blow but thats a step backwards. Not sure how i am going to chase this blow without the core on it as it wont idle with the pipework off.

At the moment im on a major downer. I had hopes of getting to Japfest (tickets need to be ordered today) but i wont want to go without my car. I also need to get the mot done which isnt going to happen with the above problems.
I did feel like just selling up but i suppose this is just one of those things with a budget project....
Id love to just get it to a specialist and say sort it and mot it but dont think i got the funds for that.

If the missus lets me then i might try and get all the other bits solved (PS and fog light and get rid of the fan light) but have been getting a real ear bashing lately because of the amount of time spent on the car.

Anyone want a running mr2 turbo with an exhaust blow?
thomp1983
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Location: newark, notts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by thomp1983 »

Chin up mate it's a minor niggle, I'd leave looking for the issue until you've got the bung fitted that may solve it, other wise it may just be a bolt needing nipped up
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

NOT SO DEPRESSING UPDATE:

So as the weather was nice i thought id have a go at solving the current issues.

First thing was the blow. Now the engine was cold id thought i try and feel any blows and straight away i had a major blow by the top lambda sensor. I took off the sensor and found i had left some gaskets on the old cat so swapped these on to the new and used the proper nuts and that has stopped blowing. It does still sound like there is a blow somewhere but i am not going to look for this until the threaded bung arrives on tuesday for the decat.
If the manifold is going to need tightening then the plan is to remove the core from both boost hoses and hopefully we have enough give to lift it, remove the heat shields and reach the nuts on the exhaust manifold.
In the meantime i have also installed the second lower sensor in the decat as the hole was there anyway.

Next to check was the intercooler fan light. Plugged the old intercooler back in and the light went. The original idea was to fit the fan to the engine lid but the fan i have cant be reversed and wouldnt fit the way i wanted so I have just temporarily installed it in its previous position for now....so thats that problem sorted.

Third item on the list was the power steering not working and light on. I removed my bluetooth adapter from the diag port and linked out the relevant terminals to read the codes for the power steering (I cant remember what terminals now but shinny had a download of the relevant bgb section on his site). It said no power to the rack (flashed once then once). Checked the 80a fuse and that was ok so next on the circuit was the relay. I couldnt hear this clicking over so joined the two giant cables into one and the power steering now works and the light is not on. Problem not completely solved but ok for mot for now....will buy a new/secondhand relay when i can. Not sure what this relay is needed for actually?

Fourth on the list was the non-working fog light. I checked the loom that it was originally plugged into for earth and live and then connected the aftermarket switch to these and afterwards all is working fine so nice easy fix there.

So time for a test drive (via a private local road obviously). The car was loud but boosting well to 0.8bar (will adjust the mbc after mot) and all was ok with the test drive apart from the indicators was flashing very fast indicating (see what i did there) a problem.
Also when we got back on to my drive there was a few coolant leaks which was solved by nipping up the hose clamps and refilling.

I checked the indicators and found all working apart from the front two main ones. I checked the connections and cleaned them and readjusted the bulbs and they are now both working.
While i was there i did a check on all the lights and the sidelights were not working which a quick clean of the connections solved.
I also checked the horn which makes a very weird noise (like a very low tone honk truck stylee) but works so hopefully that is satisfactory.

I also ran the cable for my charge cooler temp gauge. I am still not sure where to mount this so currently this just shows -160c lol.

So to end today i feel a bit more optimistic. I realise now that installing a charge cooler means there is a lot more things that can go wrong now. A part of me wishes i kept with an intercooler but we will see how it goes. I just want a car that i can drive now! lol

If the threaded bung for the decat doesnt work then the bro in law said he will be round so we can strip down the core and hopefully find the blowing.

Im hoping to book the mot for either end of the week or next week.

Ive also decided to miss Japfest this year mainly because it takes a lot of stress on completing the car off me and also i am really annoyed as i was last year that Japfest now charges per person rather than per car so going to boycott this for that reason too.
If i decide to go last minute then i will either grab an abandoned ticket or just pay on the gate if poss. Not too worried bout club stand etc.

Main aim now is to get an mot asap and be ready for JDMCombe and Bealieu.
Madabout
Posts: 323
Joined: Sun Jun 12, 2011 1:08 pm

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by Madabout »

Good to hear it's coming along and you sorted the issues causing negativity above.

Good luck completing.
markstevieandmads
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Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

UPDATE:

The threaded bung came today so fitted this which made it a bit quieter but it was quite evident that the manifold area was blowing.

So i decided to bite the bullet and strip off the core. I managed to gain access to the heat shield and exhaust manifold bolts by just removing the turbo hose and removing the 4 bolts holding on the throttle sock (not wanting to go through the hassle of fitting it back on the core so left the sock on the core) and removing the diy bracket for the throttle cable.
Luckily i didnt need to remove the water piping. I did notice I had a small leak on one and found that most of these water hosing wasnt tight so really tightened them up using a socket and rachet instead of a screwdriver.

I also found that one of the heat shield bolts had come off somewhere.

Anyway I got to the exhaust manifold area and instantly could feel the nuts were loose. In fact 6 of the 9 nuts was finger tight! Maybe i forgot to tighten these? So using my torque wrench i managed to torque them all up to factory specs including the helicoiled stud.
I also helicoiled the missing heat shield bolt so now the heat shield is nice and tight, the manifold is no longer blowing and i have no leaks!!
WE ARE NOW MOT READY!!!

I was so happy I took a quick vid:

https://www.youtube.com/watch?v=4Otao80 ... load_owner

I took the car for a quick blast on a local "private" road just to check all was ok and everything is fine.

So the mot is booked for tuesday am (or maybe wed am i cant remember!) . Ive bought some new connectors as i wasnt trusting that the corroded connectors on the indicators was going to stay ok so will get these done tommorow.
Im also going to invest in a new horn. Even though it does work, it makes an awful swan type honk noise so should be able to access this now quite easily as i moved the horn to under the headlight when i fitted the bumper and gt4 chargecooler rad.
The last thing i want to do apart from the usual wash and polish is to refit the undertrays back on before the mot.

So, an eventful and satisfying day today! Just a few minor things to finish the car off. Im hoping the emmisions are going to be ok now its got the decat on.

Ive misplaced the locking wheel nut key so need to find this or remove them and replace. I have a very slow puncture on the drivers front so will need to sort this to get the tyre sorted. Its been like this for over a year so will be ok till after the mot (if it passes).
Ive also misplaced my receipt for my battery. Im not too sure if its ok as it seems to go flat quite quick even when its not connected. I will just have to keep this charged until i can find the receipt. Maybe the car just needs a good run to recharge it.

So to end this post, im very happy!
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

PRE MOT UPDATE:

What a lovely day! Shame i cant use the car as the mot is monday 11am.

So i spent this afternoon replacing the weird horn for a new one. Its slightly different to the old one as had to run an earth from the terminal on the horn to the bracket it mounts on but all good now and sounds a lot better.
While i was in that area i tightened all the charge cooler pipework i could and remounted the under trays where i could with new m6s and nice big washers.

I didnt have a tap so metal cable tied the few areas where the bolts i couldnt use and got the majority of the under trays back on. When the car is running and road worthy i will try and borrow and ramp and get the trays on properly but they are secure for now.

I also chopped the old corroded indicator connectors off and installed new connectors for these so no further problems here either.

Checked the oil and coolant and all good so we are ready to go.

Im taking the turbo down to the mot place early monday morning so will fill her up with new v power and give her a good run before leaving her at the mot place with fingers crossed....

Wish me luck!......
markstevieandmads
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Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

Well shes made it to the mot place....

Image

Drive very smoothly with loads of power. Temp gauge stayed half way and no smoke like there was before the turbo swap.
Still havent found my locking wheel key so lets hope it dont need any work involving the wheels coming off lol
Fingers crossed..... and will update around lunchtime....
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

MOT UPDATE....



And.............



ITS PASSED!!!!! No advisories either!
Such a great feeling !

Thanks to everyone on imoc and mr2oc for the encouragement and help!
androo007
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Re: Markstevieandmads Budget Turbo project : PART ONE

Post by androo007 »

Nicely done chap. Now enjoy her for the summer!
craig
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Re: Markstevieandmads Budget Turbo project : PART ONE

Post by craig »

Can't beat a fresh ticket! \:D/
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

One of the under trays has dropped and must be getting caught by the wind as over 50mph they are hitting the floor lol

Do they really need to be on there? Might just remove them as not much left of them anyway. The car is rarely driven in bad weather so may just remove them and wait for a group buy for a stainless set or something.
thomp1983
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Location: newark, notts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by thomp1983 »

They do make a difference, the front end just feels a bit more floaty without them
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

SMALL UPDATE:

Had a few run outs with the car now its back on the road.
I had a few problems with the undertray by the ns front whel rubbing on the floor when going over 50mph so ive cut this off for now.
The rest of the undertrays are still there.

I also had a problem with the boost just dying off as soon as it hit peak boost. Turns out i had the mbc on the wrong way round!
All sorted now and running 1 bar nicely. Car is very quick and the chargecooler is all working fine and nice and cool to the touch unlike using the intercooler which just seemed to be hot all the time.

Ive got the car washed today ready for Japfest 2017 at Silverstone. Luckily, i managed to get a cancelled club stand ticket and passes for half the price. Also got some touchup paint to do the little bits of paintwork i damaged while working on it.

The car ideally needs a proper machine polish and the alloys refurbed properly. Im not too bothered at the moment as i want to just use it.

Hopefully later in the year I will be moving and saving some money so i may treat it to a full wrap or respray. I may even hire a booth and try and do it myself.
The alloys are also going to be treated to a full refurb and may put some toyos on the front as have really liked the way the rear feels now with them on.

Im thinking a nice candy red for the wheels or possibly the bronzy/volks ray colour.

Havent decided what colour the car may go....at the moment im thinking a candy green but may just go for a frozen white or something along those lines.

Also want a f40 style rear lid so who knows.....
markstevieandmads
Posts: 2025
Joined: Mon Aug 05, 2013 8:18 pm
Location: Swindon, Wilts

Re: Markstevieandmads Budget Turbo project : PART ONE

Post by markstevieandmads »

Bloody photobucket....

Will need to swap over to someone else
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