ClanFevers's APEXED 1992 GT-Limited (Continued)

[GDII]

A bit more progress on the harness.

Stripping out unused parts from the GEN4.

Cleaning things up.

Not looking too bad now. Next step is to start merging the 2 harnesses together to make it all work.

[lasersooby]

Lots of patience needed for the cleaning up of those connectors , looking really good

[GDII]

Tooth brush, degreaser spray and a cloth. If the engine is clean, then these need to be clean.

More progress after cleaning today. Starting to merge everything now.

Moving the power wires for coils, injectors, and VSVs to the correct location before I join them.

[Benckj]

Make sure while harness is out to check the factory joins in cables to alternator. Apparently, according to the UK site they tend to corrode and separate.

[GDII]

Make sure while harness is out to check the factory joins in cables to alternator. Apparently, according to the UK site they tend to corrode and separate.

UK rusts everything but I am checking all connections so don't worry about that.

[85AW20v]

So how long does it actually take you Phill to do the merge?

[ClanFever]

Jeez it's looking good! How many beers is it going to take to pay this one off? Or are we now talking kegs?

[GDII]

So how long does it actually take you Phill to do the merge?

It takes a fair amount of time as I'm still learning and just taking my time. First one I did was a GEN3 3SGE which is not the same as this early GEN2 3SGTE. TBH I'm not sure what the time involved is yet. I spent months gathering information for the first one and now this one I have to check everything is lining up.

Jeez it's looking good! How many beers is it going to take to pay this one off? Or are we now talking kegs?

I think you'd need to buy me a brewery now! But you know I don't drink so maybe Marsden Point Refinery!

[GDII]

A bit more progress on some major parts of the harness.

Power wires have been connected to some important bits.
Boost controller VSV
Fuel pressure up VSV (for increasing fuel pressure on hot start)
Idle valve
Oxygen sensor heater

Sensor list

Sensor heat shrink

Also power to injectors. I don't have big enough crimps to join all 5 wires at one point so I've done it this way.

Injector power

Injector wires covered

Joint the coil power wires too in a similar way. These also have the audio filter wired into coil 2.

Coils

The missing ECU plugs are on order to provide power to the ECU along with a few sensor inputs and outputs as well as the OBDII port stuff.

[GDII]

No photos with this one but I have connected a few more items.

Oil pressure switch connected to the dashboard light. Removing the GEN2 plug in the process.
Coolant temp sensor wire from the 3 pin GEN4 plug connected to the dashboard gauge. Removing the green GEN2 plug in the process.

Labelled a few wires so I don't have to keep going back to the spread sheet for reference. 1 wire was for the Tachometer, the other was TE1 from the OBD1 diagnostics port. The OBD1 port is still used even though the GEN4 ECU is OBD2. You can still do a CEL flash test using TE1 and E1, also other MR2 specific testing is still able to be used that was not part of the MR2 ECU. It's not easy to connect to a GEN4 ECU with some OBD2 scanners or adapters.
The Fuel Pump jumper is still able to be used too although there is some modification needed for turbo to NA to connect this jumper wire at the fuse box for the NA body.

[GDII]

A little more progress. A bit tedious but worth doing it this way.

Moving all the ECU wires through the MR2 fire wall boot. One buy one, depin then move it through the boot with a looped bit of thin tie wire, then repin back to where it came from.

Some wires already moved. There are only a few MR2 wires left that go through this boot, things like starter relay, intercooler fan ECU, Speedo and some PS stuff.

1

The thicker Black wires are the shielded components. These have up to 3 wires within.

2

Threaded the tie wire through and placed the ECU wire into it.

4

Pull it through the boot and reconnect back to where it came from.

5

6

7

At some point I may shorten the harness as it is far longer than it needs to be outside of the boot. But for now I want to ensure the engine will run.

This is the mess that is left over.

QA1

My QA monitor is back! I've been caught!

QA monitor

I guess I'll tidy it up.... That's better.

QA2

Next step is receive the 2 missing ECU plugs that are on order and wire them into the harness. These are rather important as they contain the power to the ECU.

[ClanFever]

Have posted some of this over in the Self Isolation Car Mods thread, thought I'd do a little tidy with some of the highlights

Waiting to do the oil seals + cambelt, then going to start doing up all the bits and make sure all bolts are tight, that type of thing. Got the car out of the garage to get the leather seats in, with the leather covers from the cloth seats, so it looks the same and now the rails are a bit more rusty and need grease... haha

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Cannot wait to be back behind the wheel off that dash cluster

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One day I'll be able to drive this in and out of this garage under it's own steam. I have found some rope and a multi wheel brace is excellent in pulling the car in, while someone pushes - the driveway and even the garage is on a slight downhill, so you are pushing the car up hill when putting it back in. I wonder if the pulling is easier for me due to leg presses, what should I work out so pushing is easier? The driveway is also stoney and sometimes gritty with dirt, the garage is clean so no slippage...

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Leather (well not, fake suede inserts) door cards to go in, just not doing it until I find the passenger window motor... it's around here somewhere.

[lasersooby]

Looking good mate, keeping fingers and toes crossed for you and Phil

[ClanFever]

New ECU, in

GT Door cards, in

Oil pump, therefor Cambelt, cover and crank pulley, on (the cable ties were there to help hold the cambelt while it was all placed on, they're not there now...)

Towbar, I need an angle grinder and to convince Phil it's okay as it's not for towing but for other reasons like rear end protection and shin hardening

The "Basic" list for remaining jobs is Axels, Intake piping, turbo/exhaust, wiring + all pipes that contain fluid and the fluid inside those pipes. And the rest...

[GDII]

Some actual engine progress! Being that the car had a GEN2 3SGTE with a CT20b strapped onto it a while back, Olaf decided that he wanted to keep the CT20b and swap out the standard CT15b. This means that you need to use a GEN3 3SGTE exhaust manifold as the GEN2 head doesn't match the GEN3, 4 and 5 3SGTE head bolt and port shape.

I swapped over the turbo to the GEN3 manifold and also while I was at it, checked that the waste gate flap wasn't hitting the down pipe, it wasn't.
As these are used gaskets I wanted to make sure they wouldn't leak so I used some Copper Gasket Cement as an additional measure.

A trick for new players, always put the nut on the stud before fully bolting down the downpipe or you'll never get the nut on.