The little Bosch pump I got off eBay for $40 isn't enough for the new turbo engine.
So I ponied up for a Bosch 044 and threw it in a few weeks back. Super loud! Plus, the fuel pressure shot up to 50psi as the pump totally overwhelmed the stock fuel pressure regulator. So the little Bosch went back in the for time being while I worked out a plan.
I figured an OEM style pump would be ideal for keeping the noise down, so I searched for cars with big engines that use inline fuel pumps. Turns out 993 Porsche 911 Turbos use an inline pump. I reckon the pump used in a 400+ horsepower turbo Porsche ought to be enough for my modest 7M-GTE. So I got an OEM replacement for $70 shipped.
The Porsche OEM replacement next to the Bosch 044. Bosch on the right
Bosch on the left, with the larger inlet and screen filter.
Next to the old pump I removed!
I got the wrong fittings for the fuel rail, so the install is delayed for a bit
Fuel pump upgrade done! Got the fittings, plumbed in the Nismo adjustable fuel pressure regulator, and set the pressure to 38psi.
The pump is LOUD
Going to have to do something about that.
Also done is the intercooler upgrade! The tiny, Mazdaspeed MX-5 factory intercooler is out and replaced by something much better. I painted the end tanks black, then just gave a light dusting to the bar and fins. Looks dark, but it's just a light coat on the front to hide the intercooler. With the grill back on, the intercooler disappears.
With both these upgrades, the car really moves! Revs smooth, feels powerful. Super fun
Also, I moved where the BOV gets its vacuum source from the intercooler pipes to the intake manifold. That made a huge difference, as the BOV no longer flutters at all and sounds better. I'll try to get a video up soon
Not a lot going on lately. Put some shorter springs from an older Corona in the front, along with shocks from a 1968 Chevelle SS. Lower, but not dumped. Looks much better without the ridiculous wheel gap I had before
Just had a nice Borla muffler installed, plus new tips for a little bit of flair. The new muffler isn't much louder than the old Magnaflow, but sounds much better
I bid super low on this and forgot about it, not really thinking I would win. No one else bid, so I did. "EVC" isn't all that descriptive to me, so I put some stickers on to remind me of the function of this device. Mounted in the glove box.
The car has been giving me lots of problems, all electrical I think. Given how crappy all the temporary wiring I did in the beginning just to get the car going was, I'm not surprised.
The two serious issues: code 52 (knock sensor) and severe hesitation under acceleration once the engine was warm.
When the hesitation occurred, I often also got code 11 (ECU power interruption)
This prompted me to finally get around to fixing all shoddy wiring I had done.
I started by fixing the brittle and cracked Camshaft Position Sensor wires by soldering in new terminal wires
Then I started on the big rat's nest by the alternator where I had several in-line fuse holders wired in with crimp barrels and the battery circuit ties in. You can see how messy it all was.
Soldering big power wires together neatly is easy if you know a trick. Start by pushing the two wires together, inter-weaving the strands.
Then use a few strands from another wire
And wrap the connection
Before connection and soldering, don't forget the heat shrink
Work in progress, using a nice fuse holder
I had previously used a drink bottle as a coolant over-flow, hoping it would look cool and rat-rod like. What it ended up looking like was that I had used a drink bottle as a coolant over-flow. Crap.
Wiring coming together, ignitor moved and less conspicuous, fuel injector resistor moved and almost hidden. Also used the OEM diagnostic port mount and attached it to the intake manifold. Looks almost like it could be factory
Other side of the engine was a mess too, with a big wad of tape and unused wires on the OEM harness. I bought a few feet of that old-fashioned asphalt-coated fabric loom and cut out unused wires and re-wrapped everything for (what I think) is a cleaner look.
New coolant overflow tank, actually for a MKIII Supra
And the overall look, contrasted to how the engine bay looked when the car first ran
Still lots of work to do, but the I'm making progress bit-by-bit.
Test driving, I think the engine hesitation is gone but got code 52 again. I'll figure it out eventually….
When I first got this car running, I ran extra wire lengths and used crimp connectors for quick working. Crimp connectors work well in the short term, but I don't want to leave them in. I've read crimp connectors can cause reliability issues and strange electrical issues over time.
Pictured below is the main power plug for the ECU harness. I cut this off a junkyard car to have a nice OEM connection, and as you can see there are many wires I don't need. I de-pinned the whole connector save for the few wires I'm actually using.
After (with power wires for gauges and etc tied in)
Copied Whit and mounted the ECU under the parcel shelf
In progress, getting things cleaned up. Wires under the dash now incased in the asphalt coated fabric loom to ensure long life
And done. Before, the parcel shelf was a mess of wires. Now, sitting in either driver or passenger seats you can't see much of anything. All wires tucked up out of the way.
Still work to do before I drive again, but I'm really happy with my work so far.
Still working on the interior. Printed out new labels for the boost controller, and still didn't manage to put them on straight.
I'm sure a few of you noticed how ratty the carpets I put in last summer looked. I hadn't ordered enough carpet for the whole car, and ran out when doing the fronts. So I ordered some new carpet to re-do the front area.
Start with more sound-deadening material for the floors.
Didn't realize that I purchased from a different supplier. New carpet has much more exaggerated loops. I like it much better. Too bad I had already glued-down the rear before realizing I had two different carpets!
Bar mats for the rear
I did my best to cut and shape the carpet as well as I could. Much, much better than my first attempt. Still not perfect.
The sharp-eyed among you will have noticed that in previous photos, my boost gauge was stuck in vacuum. No idea what happened to it, just stuck that way.
Options for mechanical, 2 and 5/8th inch, white font with a white indicator needle boost gauge are about two. So I went with the Autometer
Still work to do, but the car should be back on the road this week. Not so much time these days, thanks to this little guy
Finally drove the car again today! Has been about a month and a half since the car stranded me and was towed home.
Wiring, carpets, patched a flat tire, and a few other details all done at last.
Turns out the problem was in fact the Cam Position Sensor wiring. I swapped the CPS, and put a new OEM connector on the harness side to match the new terminals and that did the trick.
Car drove great! Felt better than ever. For a mile or so....
Knock sensor code came back and ruined my boosty fun, but now I also get code 42 and code 51.
I'll fix the problems eventually. But for now I'm happy that all the re-wiring seems to have been done right, the car is quieter thanks to the sound-deadening, and nicer to be in thanks to the carpets.
Not having 5th gear relegates a car to a local-only around town car. 5th gear in my car was super loud, so I never drove far. Never mind the constant little problems, the transmission has been the big issue.
Finding a W58 or R154 transmission is difficult, never mind an affordable one. Finally got one a few months back, and at last found some time to do the swap.
Three days of hard work in a heatwave really did me in! But the job is done at last.
Really not a lot of bolts actually, but the three at the top of the transmission are so hard to get to, I had to take a lot of other stuff off first.
You can see here the turbo elbow has been leaking. I think because the flange isn't flat. I put a second gasket in and that seems to have sealed up the leak. No more exhaust leak noise and soot on the turbo
Working on this surface with the car only 18" off the ground is terrible. I use a camping roll to keep the rocks from chewing me up too bad, but it's still hard work
Thanks to some help from my brother, the transmission is finally out! Old transmission with the longer shift housing at top is from a MKIII Supra non-turbo. Replacement W58 at bottom. Not sure what car it's from, hopefully it is actually a W58 or I got ripped off!
Replacement in at last. Very hard work for two guys to bench press the thing into place in such a small space under the car
New shifter further forward, and actually in the correct place for a Corona! Good thing I only cut and peeled back the metal underneath, so returning the trans tunnel to stock will be easy.
Need to change the angle of the shifter though, too close to the dash now.
Test drive didn't go well. Firstly, the new transmission is really noisy. Has me VERY worried. I realized though I put 75w80 Redline synthetic in, when Toyota calls for 75w90. Could that be why? Also, the brakes are doing this super annyoying thing where they gradually apply force as they warm up, until they are on and dragging fully, making the car un-driveable.
Hopefully this weekend I can fix the brakes and put the proper fluid in the gearbox and take a real test drive.
First, the brake problem was just free-play adjustment at the booster. I cranked down on the actuator rod to shorten it, and problem solved.
The transmission was still noisy, but seemed to get quieter as I drove. Not sure if that's just in my head and I was getting used to the noise or if the old box just needed a few miles to get the fresh oil worked in.
Did a few miles on the highway, and the car was great! Very exciting.
The car gets a bit of attention too, because it is an odd-looking and rare old thing. I imagine people are asking themselves, "What is it?"
Been a while since I updated, just in case anyone is still out there.
Still working on cleaning up the engine bay. Wrinkle finish black helps make pipes and things look maybe passable as factoryish.
Also recirculated the BOV. Even with the anti-stall valve, I just couldn't live with the driveability issues. At part throttle under load, the BOV would vent boost making the engine run super rich and bog. All fixed now. Drives like a stock car. The pipe-forest is a little much, but at the time I had the BOV flange welded I didn't think I would need to recirculate. Oh well.
Also found an intact timing cover and a coil-pack cover. The Coil-pack covers are getting rare. This one came from Australia.