IS300 2JZ-GE NAT #no compromise

[rob_clio172]

Progress has slowed right down now, hoping to to get back on track soon. Got the power steering pump and dipstick sorted today, not many pictures so doesnt look alot but was quite time consuming.

The original location of the dipstick is now blocked by the new inlet manifold and it also bolted to the old inlet. So i had to reshape the dipstick tube still allowing the dipstick to go in and out easily, find a new way to bolt it to the engine whilst keeping the lower end in the sump flush so there is no leaks. Took a while but i got there....

as you can see i managed to get it into a decent place and it also fell lucky that i could bolt it to the same hole that that the oil feed pipe for the vvt-i bolts too!

It was made very tricky because as you can see in the next picture it was in the way of the powersteering pump so i also had to bend it slightly out the way of that.

I also gave the pump a quick spray aswell as the silver bracket for it, as you can see ive had to remove the reservoir as this was being obstructed by the inlet and throttle body. Im going to order a union pipe for the supra pump and relocate the reservoir.

Still need to sort the valve shims, its all been measured i just need to get round to ordering them.

[rob_clio172]

Engine mounts have come, cant wait to throw these on, i did say i didnt want the competition vibratechnics mounts but with the inlet so close to the suspension turret i cant take the risk. 

[Bempa]

I'm pretty sure the forum rules says no porn [emoji7]
[emoji23]

[rob_clio172]

20 minutes ago, Bempa said:

I'm pretty sure the forum rules says no porn

😂hope they dont take it down

[rob_clio172]

Managed to tackle a couple of problems today, i picked up my relocation union for the power steering from toyota in the week. But this then presented another problem... the throttle attachment for the cable would not be able to go fully open due to it hitting the relocation union, so i decided the flip the throttle 180 degrees..

I then had to flip the throttle position sensor 180 degrees too as with the connector pointing down this would have hit the power steering pipe to the pump. Not ideal as i wanted to keep the exposed wiring to a minimum to keep it all looking clean and clutter free, on the plus side the throttle cable will now be completly hidden under the manifold.

But i still have 1 more problem, the union i have fitted is close to the manifold so im going to need a 90 degree silicone hose and see if it clears. If not im going to trim the union down slightly to make clearance, this union is not under pressure as its just pulling fluid from the bottle so even if the lip on the pipe is cut off it should still hold a pipe clamped on. I could always get a small lip welded on if its not going to hold too well.

[rob_clio172]

Todays job i pulled the engine back out and changed the engine mounts over to the vibratechnics 1s.

Also managed to sort a coolant hose under the exhaust manifold to the back of the water pump. I had some left over reinforced silicone hose in my box so cut a short section out and trial fitted it. Once i had it measured just right i pulled it back off, put some reflective heat tape on it and refitted using mikalor hose clamps. Had to put reflective tape on it as it sits very close to the external wastegate pipe.

Ive also removed the loom again to start modifying it to fit, ive labelled up all the plugs i will still be using and the rest is coming out, ends heat shrinked and taped up. Its looking like i will have to lengthen this loom to like i had to with the body harness. Pictures of this to come once im chopping and heat shrinking.

 

[rob_clio172]

So i carried on with the loom.....

I took over the front room whilst the other half was at work 😂 started by pulling all the tape plastic coating and clips off it. I then started chopping out plugs i no longer need. I could have just gone for the plugs but by tracing the wires back as far as i could it would make the loom alot thinner and smaller. This lot came out....

There is still a couple more plugs to go too, i then pluged this into the ecu box to see if it will all fit and it does quite nicely. Just need to bang it back in the bay now and see what needs to be lengthened.

once that is done i just need to get some sleves for the loom and get it all tidy for fitting.

[Neil E]

More good work and attention to detail. I like the way you think of everything, even down to the practical colour of the broadloom. 

[rob_clio172]

15 minutes ago, Neil E said:

More good work and attention to detail. I like the way you think of everything, even down to the practical colour of the broadloom. 

Thank you 👍looking forward to getting it all hooked up and the transmission in. I went to a trackday at bedford on the weekend with a couple of friends and it was so frustrating not being able to rip round myself...... but its things like that that push me on more to pull my finger out

[Neil E]

17 hours ago, rob_clio172 said:

Thank you 👍looking forward to getting it all hooked up and the transmission in. I went to a trackday at bedford on the weekend with a couple of friends and it was so frustrating not being able to rip round myself...... but its things like that that push me on more to pull my finger out

Yes it's great to have a little incentive and the sense of anticipation of the speed thrills ahead.That day will come but you are also sticking to the principal of getting it done in the very best way possible and as well as being something to take pride in, it should also provide the same satisfying buzz as each stage is completed.

Oh speaking of pulling your finger out, I forgot to say, we need more updates and completion by May or we release the loom on the carpet pictures to Mrs Rob 

[rob_clio172]

20 hours ago, Neil E said:

Yes it's great to have a little incentive and the sense of anticipation of the speed thrills ahead.That day will come but you are also sticking to the principal of getting it done in the very best way possible and as well as being something to take pride in, it should also provide the same satisfying buzz as each stage is completed.

Oh speaking of pulling your finger out, I forgot to say, we need more updates and completion by May or we release the loom on the carpet pictures to Mrs Rob 

she would probably cut the loom up if she finds out. Thank you for the kind words Yeh it was such a good day, i went with 2 guys who have e46 m3s, they are trying to convince me to  throw the 2jz in an e46........... no chance it would probably pull the floor pan out with all the issues they have with cracked spot welds . 

[TigerFish]

Awesome work man. Great attention to detail [emoji41]


Sent from my Iphone using Tapatalk Pro

[rob_clio172]

On 06/04/2018 at 8:16 AM, TigerFish said:

Awesome work man. Great attention to detail


Sent from my iPhone using Tapatalk Pro

Thank you 👍 means alot to hear these comments guys

[rob_clio172]

Almost done with the loom now, managed to sort all the injector plugs, TPS, power steering, cam sensor and vvti controller. Wires cut, loom sleeves fitted then rejoined the wires with solder and heat shrink. I then put heat shrink on the sleeve ends to stop them moving and fraying open. Its turned out pretty well! So far ive only had the lengthen 3 lines, this was for the TPS, vvti controller and power steering.

Still got some more to go and looks like the coil pack wires, alternator plug and crank sensor will also need the be lengthened. Just had to order another 5 metres of loom sleeve, suprising how quickly it gets used!

[rob_clio172]

Long overdue update but i have managed to get loads done! Since the last update i have also been to japfest with a friend who was part of the rx7 FD owners clubs, fair to say for a couple of days after i was pretty much deaf 😂😂!!

Had a class day, there was a huge lexus stand there on the infield but i couldnt find the name of that particluar club, there was quite a few modified is200s and 300s too. 1 in particular was a is430, v8 swapped, had loads of other work done to and sounded amazing!! I also spotted a few is200 turbos and a couple of 1jz swapped is's too but didnt find a build like mine which did make me happy..... unless the bonnet was down and out of sight.

Anyway enough of that and on to the update....  ive finally finished the loom! 

the only bit not done is the long green and red wires as these go to the gearbox and until the box is back in im not sure how long they have got to be. I had to lengthen the ignition coil wiring, crank sensor, tank vent valve and alternator plug aswell on top of the 1s ive already had to do.

Also found a percect place for the tank vent valve on the bulk head. I attached the hose from the metal line from the tank to the valve, just need to sort the hose from the valve to the inlet now.

Then pulled the engine back out and attached the loom, this is by far the best way as i could get all the way around it, tie up and tidy the loom.

Whilst the engine was out i fitted the inlet take offs for the boost gauge, tank vent, brake servo.... Also fitted the fly wheel pilot bearing

Then decided to fit the aircon lines back in as this would be a pain with the engine in, also secured the extended section of loom i made. It worked out quite well as i had some left over loom clips and a couple long studs which i screwed into some perfectly placed threaded holes.

Then threw the engine back in and connected the loom up to the ecu box, had a good look around made sure the loom and air con lines are not rubbing on anything. 

over the moon with how this has come out!! Starting to look like a proper engine bay again now. The ecu relocation has come out better than i ever imagined, all lined up perfectly and looking very OEM!

Next on the agenda, valve clearances..... been putting this off way too long!! Get the crower cams fitted, valve covers powder coated, cambelt and covers fitted and sort the power steering bottle, lines and cooler.

[Neil E]

It's coming along nicely. Do you have a finish date in mind? I ask as a well spoken chap called Harry from central London phoned earlier, said he was having second thoughts about something and might need a very fast getaway car early Saturday afternoon.

[rob_clio172]

😂😂 might have to charge extortionate rates as i know hes good for it 😂.  To be honest though she is hottie im guessing he wont be running anywhere. On a serious note i have no idea, im thinking its going to be next summer now before its mapped and ready to use in anger

[Neil E]

41 minutes ago, rob_clio172 said:

😂😂 might have to charge extortionate rates as i know hes good for it 😂.  To be honest though she is hottie im guessing he wont be running anywhere. On a serious note i have no idea, im thinking its going to be next summer now before its mapped and ready to use in anger

Sounds like I may need a ticket to Japfest 2019......

[rob_clio172]

1 hour ago, Neil E said:

Sounds like I may need a ticket to Japfest 2019......

Now that would be great to make it to that! I will be there either way.... will be amazing if i could give this a shakedown on a track session. 

[rob_clio172]

I also had something else turn up a couple of weeks ago, ive completly forgot to post it up on here. 

I decided to order my Tial 44mm wastegate and Tial Q blow off valve, i ordered with real street performance again as the previous experience with them was exceptional and wanted to avoid the huge amount of fakes doing the rounds. Once again Robert Del Angel sorted me out and just like before my parts came in 3days from florida!!! Also threw in a couple of decals too.

The wastegate came with every spring available, v band clamps, spare v band flanges and all the fittings required.

The blow off valve also came well packaged also with the weld on flange, clamps and fittings.

Cant wait to get the wastegate fitted, blow off valve will have to wait though until the intercooler pipework is sorted.

[rob_clio172]

More progress, the agenda went out tbe window though as i had not got my small torque wrench or any large spanners at home to do the valve clearances so i decided to throw the clutch on and gearbox back in.

Spec twin disc in all its glory.

now here is when the fun began! So it turns out the twin disc with flywheel is so thick that i could not get the bell housing to clear it and the transmission tunnel 😓  so i lowered the box and unbolted the clutch assembly back off the flywheel. I had to put the clutch assembly on the input shaft in the bell housing and put it all in as 1. Then had to locate the clutch dowls through the side access holes! Luckily the bolts was in the perfect place to access them through the hole for the slave cylinder to torque them up.

once that was done i then had a little spare time to do another job i had also not planned to do so early...... i got the wiring routed through the bay and into the car for the AEM air fuel ratio and boost gauges. This was very straight forward as once again lexus/toyota had obviously known that at some point in the future i was going to be doing this 😂😂

They even put a big arrow on the main loom grommet guiding me home 😂 that slice you can see was already there but covered by a blob of sealant so i just pealed it off.

just need to apply bit of sealant now to gob it up so water doesnt get in

[rob_clio172]

So since ive dropped the box back in a problem has shown its head which i never accounted for...... with the weight of the box now bolted up, the engine position appears to have shifted slightly. It has now caused the manifold which looked to have had around 5mm of clearance on the suspension turret is now touching it!

This is bad news, im now going to have to pull the complete engine and box out and figure something out.

Im going to try and shave the turret on that side, aslong as i can get 5mm of clearance i will be happy but it may be a case of cutting a section out and having a straight section welded in.

So tomorrows job is to pull the lot out if the rain holds off for a bit and get the grinder out! 

I have also modified the gearstick boot cover whilst i had little bit of spare time.

Cut the edges off so it sits flush and cut out a small section for the gearbox vent.

Also cut a section from the body work for the vent.

Gave it a lick of paint then trial fitted it.

Just need to get a small rubber section now to cover the vent to keep the fumes and roadnoise out.

In other news the body kit has turned up, bit rough around the edges and will take alot of work to get it good but it comes with the territory of having a fibreglass kit. Not going to post pics yet until i come to fitting it all so will keep this under waps.

[Neil E]

5mm is a small margin for clearance but it seems odd that the engine position appears to have shifted.

Yes I agree with that, nearly all fibre-glass body-kits whether cheap or expensive, need some work. I quite like to modify them just a little too so that it has your own 'stamp' on it.

[rob_clio172]

16 hours ago, Neil E said:

5mm is a small margin for clearance but it seems odd that the engine position appears to have shifted.

Yes I agree with that, nearly all fibre-glass body-kits whether cheap or expensive, need some work. I quite like to modify them just a little too so that it has your own 'stamp' on it.

Yes its very strange, i have no idea why or how its happened but it has. Very annoying, ive been looking around the engine bay to see if its affected anything else and the air con pipes are also looking very close to the manifold aswell. The only thing i can think of is with the box in the engine is leaning back slightly, maybe if i lift the box up higher it will create clearance but i will need to check the custom propshaft angle in a higher position.

Yeh 5mm is not alot but those mounts are very stiff and im expecting next to no movement so im hoping it will be ok. 

Im looking forward to the kit as ive never done anything with body kits before so this is all new to me, maybe asking for some tips 👍 

[rob_clio172]

Attacked this issue today, it was really bugging me! Ripped the engine and box back out, suprisingly very very easy with the box attached, the weight of the box put the engine at a good angle to lift out.

then attacked the turret with the grinder aswell as the side of the manifold. The weld on the manifold was pretty thick so i just flattened this off. I did have pics of the turret half way through the process but they was blurry, wished i had checked them before carrying on!

1 of the manifold weld.

 

Then gave it a rub down, bit of primer and quick spray with some gloss black and threw the engine back in. Again these pics was blurred! So moment of truth, all bolted up and in position there is clearance of around 4mm, im happy to let this go and see how i get on. The mounts are solid and even shaking it side to side using a bar there is no movement at all just the whole car shook 😂

Very hard to see the clearance on the pic but im happy with the out come.

Just for the fun of it i decided to quickly hang the rear section of the exhaust up....

its so so big compared to the original exhaust, i bet my neighbours saw this and thought oh god there goes the neighbourhood 😂

so now im back on track next up is the valve clearances, need to order me an adjustable exhaust gear and cambelt. Also looking to sort the additional loom for the AEM v2, this needs routing inside the cabin and behind the glove box. I have already previously cut the hole for this on the inner wing and i have now got a door loom grommet to use.