GDII's 1990 G-Limited

[GDII]

And we are back on the road! All WoF'd and rego'd up for another 6months to a year! Still rocking the 3SGE but it's still plenty of fun.

Not only am I excited to have it back on the road and able to drive it, but this little dude loves it. Screamed at me when I shut off the engine! Already a car mad kid. Who would have thought?

[Swampy]

Awesome, everything's so shiny. Bit surprised you got parts from Aliex

[GDII]

Awesome, everything's so shiny. Bit surprised you got parts from Aliex

Yeah doesn't sound like me ay? But... why pay for the same product with a brand on it if you don't want the brand name. These were about 20% of the cost of what you pay here for a product you can't even get here. Yeah I pay TRD tax but that's a different story.

[GDII]

I finally got the right dust cover! The one that was wrong was required anyway. Part number 41336-12020.

This goes on the right hand side axle and protects the oil seal in the E153 gearbox.

[GDII]

Flywheel time! This will get a full resurfacing and 3 new dowel pins. Part number for the pins is 90250-08054. I'll update when that gets done.

This is the 3SGTE flywheel from another GEN4 3SGTE. You need this to fit an E153 clutch. I have a 3SGE in the car right now so it is smaller and will not fit. I guess the cat is out of the bag if you hadn't already figure it out, I'll be running an E153 instead of the S54 gearbox.

[GDII]

New flywheel bolts, 8 of them. Part number 90105-12187. The Caldina engine I have is from an automatic transmission car so has a flex plate with bolts that are too short. So here are some new ones to bolt the flywheel up.

Don't forget to use a thread sealer when installing these as they actually seal the holes in the crank shaft to the crank case. Not good having oil leaking from here onto your clutch.

Toyota recommends Three Bond 1324 or TGP part number 08833-00070.

[GDII]

Some new exhaust manifold heat shield bolts. Part number 90105-08222. These tend to get very rusty and seize but luckily mine came off with no dramas. You can see in the last 3 images the existing ones. Not so happy. I believe I used an 11mm socket to get them off due to the amount that had rusted off.

[lasersooby]

Looking good mate, soon we'll have to wear sunnies to look at the assembled engine. Pretty cool mate, looking forward to the final assembled product before it goes into the engine bay

[GDII]

Some new OEM hose clamps. Part number 90467-15004. PNC 16285A in the part diagram. These go on the coolant hose for the turbo. The hose had been replaced previously with some non OEM hose and some worm drive hose clamps. A perfectly fine fix but... I wanted to go back to OEM so I've bought some new clamps to replace them along with a new hose in a previous post. Sure I could have found some used ones from another engine but they don't cost much new and these are the exact right ones.

I love the little grenade pin clips that hold them open until you put them in place.

Screenshot_20210626-152832.png (482.76 KiB) Viewed 1230 times

[GDII]

Looking good mate, soon we'll have to wear sunnies to look at the assembled engine. Pretty cool mate, looking forward to the final assembled product before it goes into the engine bay

I'm not quite sure what I had in mind for this build. It sort took a few different turns but I guess what I didn't want was put in a dirty engine with corrosion on it. Not trying to go show car build but just something that will last another 31 years.

[GDII]

New nuts for the turbo oil feed and return. Part number 90179-08054. Mine weren't in the best shape. They get rather hot and rust.

Screenshot_20210626-152024.png (507.76 KiB) Viewed 1229 times

[GDII]

New cam pulley bolt. Part number 90901-19041

I managed to stuff my other one trying to get it off. Ended up grinding it down to fit a 13mm socket over it as shown in a previous post.

[GDII]

New bolts to connect the turbo B pipe to the turbo muffler. Part number 90105-10023.

For now it's just a standard B pipe I picked up from lasersooby many years ago in preparation for this swap. It bolts up to the TRD 3SGTE muffler so that makes things easy. It's definitely nice to get these bolts for this setup rather than some random hardware store setup.

[GDII]

New gearbox drain plug. Part number 90341-18033. My one is a bit damaged so good to get another. I have the new washer as part of the gearbox rebuild seal kit that I previously posted.

[GDII]

New PCV hose from the PCV valve to the intake manifold. Part number 12261-88580. Mine was in OK condition but best replace it now so it has another 24+years life.

For those who don't know what PCV stands for, it is Positive Crankcase Ventilation. These engines, like most of this kind produce a positive pressure inside the crank case. It needs to be ventilated to stop the oil seals from being pushed out. The pressure comes from the movement of pistons up and down and blow by. All engines produce blow by from the combustion chamber no matter how fresh or well built the engine is. This is exhaust gas getting past the piston rings into the crank case.

This is one of 2 paths to vent this pressure. It is controlled by a vacuum valve that opens up letting oil vapour into the intake manifold to be burnt as part of emissions control during off throttle and idle events. When boost pressure is applied it shuts off to prevent boost pressure getting into the crank case.

The other path is an open vent to before the turbo. This doesn't have a valve. What I found interesting though is that it has a large pipe and hose, about 19mm or so to the stock intake hose but on the hose is a much smaller hole. A curious observation.