Bit of a small update, progress is slow and the more I remove the more botches I find!
Started off by giving the AFM a good clean as the previous turbo failure had resulted in thick gunk everywhere...
not only had the flange been butchered but the adaptor left a gaping hole that allowed air to bypass the air filter.
luckily managed to pick up an RC AFM with K&N filter (that is fitted properly) and even came with a loom extender to allow a straight air intake to be fitted and still connect the AFM wires.
I have been trying to figure out the best way to connect the turbo oil & water lines.
Whilst teh TB Developments turbo kit did come with some (it was a used kit) they were for a T205 and I was not happy with most of them.
e.g. oil return pipe had loads of joins & I was not overly happy with a jubilee clip holding on the hose to the turbo adaptor.
this could not connect to the connector on the ST185 oil sump.
A new threaded adaptor was fitted in place..
and a 90 degree take off installed that woudl accept a braided hose.
the turbo end requires a special Garrett adaptor with flange that I had a length of braided hose crimped & swaged to (think automotive) which minimises the number of connections and doesn;t mena you have a jubilee clip in teh near vicinity of the turbo being subjected to the heat cycling.
I still have to cut the hose and tighten up the connection but it also located the oil drain braided hose away from the downpipe and block whilst maintaining a downhill direction for the oil flow.
Unfortunately after 4 weeks I am still waiting for the turbo oil feed adaptor to come in to stock at Think Auto which will allow me to complete the turbo oil setup.
Water feed & return.....
The St185 has a rather different water flow layout to the ST205 which has taken some time to understand. I had orginally intended to install a swirl pot in the top rad hose and add another water connection to the turbo.
standard water hose arrangement
I had wrongly assumed that this was the water return line and not the feed but on closer inspection of teh Toyota coolant flow diagram it appears that the return runs back in to one of the metal pipes running along the front of the block and as such the feed is the one shown in the above picture (can't use the swirl pot they way I had intended, not sure if I can take the water feed for turbo from the bottom of the swirl pot though). I will scratch my head a bit more to come up with my preffered option.
I am slowly gathering bits to facilitate the install of the DTA S60 Pro ECU
Oil & Fuel Pressure sensors with flying leads and Loom plugs. Turbo boost pressure control valve (VAG part) Made in Monaco! explains the pricing I guess. Some new ECU loom plugs to allow me to build up a loom.
I was also lucky to be offered these items:-
I hope I can use this to make a DTA loom adaptor. It was orginally a Toyota diagnostic cable for an auto box. the little chip has been identified as an LED driver (could be handy to swap the feed to the chip from the Auto box to the Knock sensor to create an LED knock meter?)
I also picked up this test loom with the correct Toyota plugs..
Should be a good start for a brand new loom once I get brave and install Coil On Plug etc.
I have been deciding what to do reagrding fuel rail for some time and finally bit teh bullitt and purchased a speedsource top feed fuel rail. The quality appears much better than the Wolfkatz stuff I have seen.
Kris kindly gave me a set of ST165 top feed injectors so can still run the standard ECU should needs must at any point. (ST162 injectors fitted.
The intention is to fit the rail & some new circa 700cc injectors to the rail along with the St162 Inlet manifold..
I have almost completed the FMIC install, (phase 1 for ST185 inlet manifold!)I need to get my support bar welded up for the core and subsequent GB, Engine & PS coolers to allow final fitment.
The 2 bottom pipes are datajon pipes (he is also making me a top pipe for the ST162 inlet manifold) and I have made up the current top pipes as an interim measure (luckily I have a HD beading machine at work).
The intercooler was a custom design (designed & drawn up by me) to fit the ST185 and manufactured by Pace. I had high aspirations with the core but the cost of putting my bright ideas into practice was astronimical and hence I chose to compromise. Core cost was circa £350 delivered.
the above picture shows the pipe sitting incorrectly ( too low) This will be adjusted once I get hose clamps and the turbo clocked to the precise position.
Whilst at it I decided to test fit the Golpher radiator and Spal fans. (I have opted for twin blower type)
That is about it for progress at the moment.
The next phase is to get the oil cooler and intercooler support frame finished/welded and then to start fitment of gearbox, PS & engine oil coolers. I will then get turbo hoses finihsed and swirl pot/header tank mocked up for manufacture.
For reference the gearbox cooler has been removed and these removed from the GB end of the hoses...
I have purchased the cooler & adaptors and some hose taht I will mock up and then have crimped & swaged at Think Auto during my next visit!
For those geeks of you...
I picked up a TTE St185 1.4mm head gasket
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