GDII's 1990 G-Limited

[GDII]

Flywheel machined! Excellent job by Collier Motor Engineers in Levin. Same day service!

You can see in the third image the step down to the pressure plate mounting surface vs the friction disc surface. Have to keep that clamping pressure up! They took off a good amount of material to make it flat again. I will install the new dowel pins later on.

[GDII]

New head bolts. Part number 90910-02094. 10 of them.

You are probably asking yourself why not head studs? For the power I am going to get the head bolts will do fine and I'm not taking the head off all the time. You can reuse these head bolts but these weren't too expensive to go new. At less than half the cost of studs it made sense.

And before anyone says these are torque to yield bolts, both the GEN2 3SGTE and the GEN3 3SGE service manuals do not state that these are one use parts. Only if they are damaged or do not torque correctly that they should be replaced.

[85AW20v]

.... Only if they are damaged or do not torque correctly that they should be replaced

Or if they measure up over the maximum specified service length.

[GDII]

It finally happened! After 31 years the brake light switch stopper collapsed. It's a common issue on these cars and I was wondering when it was going to happen. Hopefully I can still get a new part for it as I now can't drive the car. I should have bought one ready for when this happened.

PNC is 47131and part number is 90541-06032. This is discontinued it seems so the one for the later model cars might be the only one to use. 90541-06036.

For now I'll just hit up the wreckers and get one as it comes on heaps of cars. Then I'll buy a new one with another order of parts.

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[GDII]

I'm still slowly trucking along with this project. A little side track with a stereo setup. I want to keep an OEM looking setup in single DIN but also have the ability to have Bluetooth. So the newer Toyota units have a CD changer port in the back which people make Bluetooth adapters for.

I picked up a unit from a 98 Caldina at first as a proof of concept and this is my new unit for the Corolla Sprint. Works well but the sound quality isn't as good as I was hoping. Although some of it is to do with the speakers themselves. So my Mum has a 2000 AE111 NZ new corolla that has a decent OEM system so I went searching for one. Found one in a 99 AE111 Corolla hatch. Sounds are better which is good.

Using one like this it's plug and play. It has hands free calling too and allows you to control the music track from the OEM head unit. Plus you can use USB music and 3.5mm if wanted. It has a little wired remote for a bit more control.
https://www.aliexpress.com/item/4000677 ... Jy2L2&mp=1

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Test fit the Caldina unit in the Corolla.

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Rather dirty unit. I think it also had some soft drink spilled on it.

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Took the unit face off and cleaned it up.

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Old MR2 unit which has a 13pin DIN plug in the back. I would have used this as you can get Bluetooth adapters for it but the sound is terrible. Although it might have something to do with the way I did something with the wiring. Big facepalm. Anyway, the new unit has NZ radio stations so no need for a band expander here. I was going to have it but no need for it so I took it off.

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This choc block is what the car had to bypass the OEM stereo system for an aftermarket unit. The wiring here is from the Caldina but it's the same as the Corolla setup. It's what I will use for testing then rewire it properly to still bypass the OEM setup without cutting any plugs out.

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Installed in place. I haven't wired in the illumination wiring yet as I'm not too sure on the best method to do this. Possibly tap into the illumination circuit of the OEM 15 pin plug. And I need to jerry rig the aerial to work like I did before.

I'm quite happy with this setup and the look of it. Gives that OEM look but gives modern connectivity without hacking things up. I know Levi has a direct plug and play unit but he has a GT-S so has a different wiring setup with the low spec stereo. My car already had a bypass so I can use it again.

[GDII]

I did manage to get a replacement brake light switch bumper.

Thanks to my friend Josh for grabbing me a replacement part for the brake pedal for the brake light switch. Now I'll be able to not have the brake lights on permanently!

This is actually the exact part number from the later model SW20 and it's from an ST210 Caldina. It comes on many cars. Part number 90541-06036.

[tw2]

I had the same thing happen. I replaced the crumbling plastic debris with a bolt until I could order the correct part.

[GDII]

I decided it would be safe to send off my injectors for cleaning and testing. They were a bit dirty on the outside and having had 307,000km of fuel through them I felt it would be wise to spend a little more and make sure that these were running right. Nothing worse than a faulty injector causing problems that a small fee could have fixed.

[GDII]

I gave the injectors a good clean up before I sent them off to Injectortech in Auckland. They came out quite well but not perfect.

[GDII]

Got them back from cleaning and testing. Ultrasonic cleaned so they look much better than my attempt. At least that's how they look without taking them out of the packaging.

A massive 600cc at 43psi and all within 1% of eachother. I think base pressure is more around the 34psi mark so they are rated at 550cc.

They came back with new O rings. They are green so I think they are Viton which is better than rubber. I've got the OEM O rings in the rebuild kit but I'll use the ones supplied here. Also comes with some grease for installation to make sure you don't damage the new O rings when going back into the fuel rail.

[GDII]

Final injector photos until they get installed. I promise!

[GDII]

New clutch cover bolts. Part number 90119-08079. This supersedes 90119-08026.

Thanks to a mate for sourcing these. They are a super common part on almost all manual Toyota but somehow it wasn't easy to get them from my usual place. Off to Impex get them instead.

[GDII]

New MR2 Heaven GEN4 swap throttle cable. This one is quite a bit longer than the stock GEN2 or GEN3 3SGE one making it reach the throttle body better with less strain. It's at least 400mm longer than a GEN3 3SGE one.

One main difference you'll see in image 4 is the front firewall mounting is different between REV1 and REV2-5 JDM cars. The new one on top is I assume designed for REV1 which my car is and all of the USDM cars. Unless they were changed with the JDM cars. You can still bolt it in with one bolt. For me it should be a straight swap.

[*84vvt]

I replaced my clutch bolts with cap screws , easy to get from local bolt suppliers

[GDII]

These were free.... And OEM. You know how I roll.
Mostly the reason I got them is, I have some on the 3SGE but I'll want to put everything together before I pull the engine so need another set.