tw2's mr2 - the journey to a clean 2

[tw2]

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[Benckj]

I notice you left turbo connected to manifold. I’d be tempted to break apart if you see any signs of leakage. I’ve had studs back off, nuts loose and gasket become cracked & deformed when running the stock ct20b. No signs of this on mine until it was inspected.

[tw2]

I thought about it but decided to leave it be. I have another manifold and the mating surface is not the best. I am worried if I pull this one apart I might not be able to get the studs out and resurface it or the studs just break. There was no soot anywhere around the gasket so I am thinking there are no leaks... yet.

[tw2]

Yay fuel tank back in. It wasn't too bad even single handed on jackstands. I taped the fuel pump electrical connector near the fuel sender unit so it would definitely be at the right place to connect inside the cabin (good tip I found on mr2oc, imagine dropping the tank again because the wiring got caught up near the pump ). I replaced the small fuel hoses and clips. The part number is in the picture but it is just normal fuel hose, the official toyota genuine replacement part isn't even the correct length, you have to trim it, save money and don't bother, generic will be fine. Just for fun I jumped the pump with the battery before putting the tank in the car. I put the jerry can at the feed line to check fuel came out. I almost cried for Marty on might car mods when he found his feed line was blocked after putting the tank back in his mr2. Pump dead on arrival would also be tragic.

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And the current state of the engine bay. Still waiting on fuel pressure regulator and one last fuel hose before I can finish putting it together, delete the fuel return line and put the new heater hoses in. After fixing the heater hose hardlines that were leaking at the bracket I found the fuel tank must rest right up against them as there is zero movement with them now.

[Benckj]

Good idea test running pump before final assembly. I did same with DC power supply but still managed to pinch the return hose when tank installed. Watched my fuel pressure hit 150 psi on start-up which was a good test of my new fittings and lines! Thankfully, I was able to work the hose free without pulling tank again.

[tw2]

Stock manifold experiment, chopping the top off.

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[tw2]

Fuel time, new feed and return line, stock return delete, stock FPR delete. Much simpler.

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[tw2]

I haven't pressure tested it yet. The only possible issue I have is that despite being very thick 6AN line, the banjo fitting on the feed line is only about 4.5-5mm ID. I guess if there are AFR issues on the dyno that will be the likely culprit.

[Benckj]

Fitting size will be adequate. Can you adjust your regulator for more pressure? Notice you also don’t have a gauge to monitor levels with.

Not sure about the gen 2’s but later models have AFPR on return side of rail. That way full flow & pressure onto rail. Looks like yours is set up to supply and return so rail is dead headed?

[tw2]

Not adjustable. It is a 3 bar Bosch regulator but it does have vacuum reference. It has a pressure gauge installed currently as per the photo but I will take it out once the correct pressure is confirmed. I might also get the M12x1.25 to 1/8NPT adapter to use at the end of the fuel rail should I need to confirm the pressure there too.

Yep deadheaded, seems like the easiest cleanest option. A lot of new cars come like that with the regulator in or next to the tank.
https://wilhelmraceworks.com/fuel-system

[Benckj]

Ok , will be interesting to see how it goes. From memory your going to run with E85 which would explain the 3 bar regulation (43psi).

[tw2]

No just pump gas, maximum driveability, wide torque curve, nothing crazy. I want to run N/A for a bit longer and the 3sge fuel pressure is 42-44psi so it should work perfectly for that on stock ecu while allowing me to have it turbo ready (apart from injectors which I can drop it just before dyno tuning).

[Benckj]

NA’ s must run higher base pressure then as I seem to recall my turbo being 32-35psi. Adjusting it up above this level made engine run very rich.

[tw2]

Update, the intake manifold experiment is nearly finished.

The delusional idea:

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No turning back now. Nice open wide tapering runners:

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There was a fair bit of test fitting for the plenum:

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Still need a throttle body cable bracket:

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Coolant neck and tree installed with all new hoses. Bracket made for the fuel feed line. NPT fittings everywhere, just waiting on one more 1/4NPT cap.

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RacerX catch can mounted. They provide a huge bracket which puts the catch can half way into the engine bay. I decided to make my own so it would be tucked right up hard against the suspension... tunnel hole thing.

[Benckj]

Looking good. Not far now from start-up.