Thanks Statek, I hope so. Has been quite a bit of work.
So what's been going on? A lot of trouble shooting.. I'll get to later though.
Firstly I installed all the vacuum lines, using thread seal on the barbs to prevent any kind of vacuum leaks:
I don't have pics unfortunately but the four ports on the intake runners go directly to the vacuum manifold (providing the vacuum source).
The remaining two ports on the vacuum manifold get connected to the fuel pressure regulator and to the ECU MAP sensor. Really simple.
Installed the injectors and fuel rail:
Installed stock ECU (Trans control module also connected):
At this point I couldn't help but test start the car. So I put in some new engine oil, some new transmission oil and connected the battery... no sparks, no heat, no fire, good so far..
Then I put the key in the ignition and turned it to the 2nd position.. dash lights came up as usual.. turn to cranking position and absolutely nothing
So the trouble shooting began, I checked the following:
- All ground wires were fine; the engine, transmission and chassis were grounded. I checked this with a multi meter (probe on battery "+" and other probe on engine, then chassis, then transmission. By doing this I got +12V at all these points).
- Fusible link was fine. I was getting +12V at starter motor cable all the time and also at the alternator. Also my headlights and indicators work fine.
- Starter motor was fine. I checked this by connecting it to the battery and the solenoid pushes the gear out, the motor also seems to spin fine.
- Starting relay was fine. I checked by providing +12V across the coil terminals and I can hear it click. I also checked the relay coil continuity with a multi meter.
Here are some pics of me testing all these things:
0V at the starter solenoid connector normally EXCEPT when I manually actuate the starting relay and then it shows +12V. NOTE: It's hard to see but one probe is on battery "-" and other probe is in the starter solenoid connector:
This is how I manually activated the starter relay (obviously I had to remove the relay cover to do this):
So! This only left the Neutral Safety Switch wiring. I suppose I messed it up because the online picture I found to help me had different wire colors.
So I was left with no option but to cut into wire harness again and find out if it was indeed the neutral safety switch causing the no start issue.
Glad to say that after I had exposed the wires they were the culprit.
I re-soldered them properly and went for another test start.. this time it actually started! Was so glad.
At this point I was really happy and continued to install a few more things like the alternator, waterpump/alternator belt etc.
I then went to fill up the cooling system with water.. this is where the 2nd problem occurred. As soon as the water level got above the water pump, water started to leak out of the top water neck (on the front of the engine. This was really disappointing because it meant I had to remove the ITB's to get access to the small metal water pipe (where the leak was occurring).
Removing the fuel rail:
Removing the ITB's:
No wonder it was leaking.. funny since I remembered to replace almost all the other seals and O-rings apart from this one of course.
New one fitted:
Finally after refitting everything back on and filling up the system with water, everything seemed to be fine. No more leaks. I bled the coolant system as much as possible without starting the engine.
At this point I started the engine and bled as much of the air out as I could. (Yes I used the Toyota manual method).
This was the first time I had the engine running for more than a few seconds. I noticed that it was running super rich. Unfortunately I think this is just due to the stock ECU fuel map being way off for an ITB setup. This is why I bought the Apexi Power FC ( I still wanted to try the stock ECU though).
Here are the spark plugs after about 30mins of running!
That's about it for now. My next task is to test the Apexi Power FC and then get it tuned. Luckily its plug and play for the 4AGE 16V (would be too much of a nightmare re-wiring again).
I'll just leave a few pics of how it sits at the moment. Was so nice getting it out of the garage and washing it: