Quote from
http://rob.carlile.home.mchsi.com/lexus/lexus1.htmIV Testing/Problems Encountered
I had several problems with setting the car up, all of which were my fault, and were not in any way related to the upgrade itself, only my installation.
The first problem I had was that I could not get the FPR to raise the fuel pressure above 23 or 24 psi, stock being about 30. This was at idle with the vacuum hose connected. I was not familiar with the adjustment on the FPR and being the cautious sort that I am, I was too gentle with it at first, fearing I might break it. It turns out that where I thought the end of the adjustment was, was actually the beginning of it, and after a conversation with Reg, I decided to turn the adjustment screw a little harder (clockwise). Now it was starting to adjust! Reg had told me that his car was set to about 7 psi over stock so I set mine to 37 psi (at idle with vacuum hose attached).
My other problem, which was a real dumb oversight on my part, was that the two hose clamps holding the rubber hose connecting the "3000" pipe to the throttle body were loose, allowing metered air to escape under boost, which caused the car to run real rich under boost. I got enough black smoke out the rear that I looked like a mosquito fogging rig from South Fla. (Made $47 fogging for mosquitoes in two neighborhoods that day) After I got my band clamps tight, the car started running much better. Now I could think about adjusting the FPR and the AFM screw to optimize my mixture.
Reg told me that the car would idle best with the AFM screw all the way in, so this is where I started. Using the Montigney V/F meter as a guide, I finally settled on AFM screw at .607 (all the way in) and the fuel pressure set to about 28 psi (idle with vacuum). This is about 2 psi under stock. The car, however had a crappy idle, and I could not seem to tweak it right. I was sure, however, that I still had done something wrong, so for three days I kept looking at every vacuum hose, connector and widget I had touched to see if I could find the culprit.
After fogging the neighborhood for most that first day, I decided that it would not hurt to put in new plugs. I also found that the #6 plug wire had some insulation missing, so new wires were also a good idea. I ordered both (all factory Toyoto parts)and put them in when they arrived. Maybe this was my idling problem. But alas, it did not help. If anything, it was worse.
I had not changed the gaskets for the throttle body or the ISC valve so I decided to do this as I was running out of ideas. Well, it turned out the ISC valve gasket was leaking a little, so that when I put the car back together with new gaskets and tested it, the V/F meter showed a change in mixture. Well, at least I had affected it, so this was good. The car still would not idle smoothly, but now I was pretty sure it was somewhere in the ignition system.
Well, with the plugs and wires, I had managed to shoot myself in the foot again. The plugs are supposed to be pregapped, so I didn't check them, and just installed them. I had also installed the new plug wires at this time. The dyno runs I did the next day were with this setup, and a close examination of the curves indicated I still had ignition problems. After the gasket replacement, I thought about it some more and finally decided that I still had an ignition problem. I pulled the plugs, one at a time and checked the gaps. #3 was about .018 in. , while the rest were .025 to .030! Pregapped my ass. I regapped them to .031 and reinstalled them. I also found that the #2 plug boot had not been fully inserted into the hole and the contact was not fully snapped onto the plug and that the #3 plug wire was not fully engaged into the coil. Because the plug wires are all held in the looms when connected to the coils, this had restricted my access to the plugs. This made it hard to see what I was doing and to get the #2 boot fully inserted. I finally removed the all wires from the loom and put them back in one by one. When I put it back together this time and fired it up, the idle was much better. Now I could go back to the AFM screw and the FPR for my final adjustments.
I eventually settled on AFM screw at 0.385 (all the way out) and the fuel pressure set to 28 psi. With the system adjusted like this, the car idles smoothly and in the green on the VF meter. In fact, the VF readings look like they did before the mod. This was my tuning target, to make the car run the same, V/F-wise, as before the mod.
With it setup like this, I have no idea where my FCO is. My boost is set at 1.0 bar, and I have not hit it once since getting it tweaked in right. My peak hold boost gauge shows max boost during shifts is about 1.3 bar (19.1 psi) so it must be above this.
I also kept a close eye on my EGT gauge. The sensor is located after the turbo in the elbow before the downpipe, next to the O2 sensor. The highest EGT I have seen is 1400 F. Reg says my danger zone begins at about 1450 F, and that my readings are good. A note here about the location. A better location for the EGT sensor is before the turbo, which will read about 100 degrees F higher than after the turbo. It was not feasible to locate it here on my application, so the elbow was chosen as next best. The HKS sport turbo provides a port for mounting the sensor before the turbo, so eventually, I'll get it located there.