KZN185 Surf: Just want a reliable horse

[fh2014]

Right

Next mission for weekend missions as the work ute gets me round at the moment. Cheap surf. Blue, 190kms never switched, but never seen a service. Opened bonnet, engine bay covered in oil like a BP pipeline spill. Drives fine, no overheating or signs of it - so the heads bound to crack soon. Not if I can help it.

Strip it right back

About 8 cans of degreaser later, turbo off, manifolds off, rocker cover off.

New water pump, new timing belt kit, rocker cover gasket - responsible for the oil paint job. New gaskets everywhere.

[fh2014]

Going for a front mount intercooler after the epic results I got on the nissan.

That intakes getting flipped no way I'm running 180 degree bends anywhere

Hardest part will be making a bracket for the different angle the throttle and kick down cables connect to the T.P.S. And that's not hard.

Throttle plate? you don't need one of those your a diesel get outta here. Yes, the intake and head ports were de-egr-gunked after this pic

EGT sensor tapped in

Aaand spot the pitting on the turbo wheel. The intake flexi was completely snapped when I took it off and someone had (failed to) repaired it with masking tape. like who needs an air filter? she'll be right. Off for a rebuild, with a cheeky hi-flow on the side.

[fh2014]

intercooler in, trans cooler in, manual oversize radiator in, viscous fan adjusted and refilled, lower temp thermostat in.

a bit of piping in, just need intake flange, hope to do some heat sheilding around the air filter as this really does make a difference. Will also later install a drivers-side snorkel from the petrol model to link up to this before diving in water.

and just because I like to go that extra mile, a recapped ecu from the intercooled model. you also need the intake sensor that goes with this so it can read post intercooler temps. part numbers if anyone wants to be as crazy as me (all prefacelift) -
non intercooled ecu 89661-3D240,
intercooled ecu 89661-3D260,
intake sensor intercooled model 89424-60010.

[fh2014]

Of course the ECU is all yet to be tested, I will leave the current one in there for a bit before installing the intercooled one. Still a couple things to do before shes back on road; intake flange, throttle cable bracket and new battery mount and cabling as It had to go to passengers side for this to work.

Open to you thoughts

[mudsurfv6]

Open to you thoughts

been a bit of talk on here lately about super charging diesels, go on go on

[fh2014]

That would be (possibly) going where no man had been before ...If there was a charger that could bolt up where the AC was easy enough I could be keen, just because I'm crazy. Maybe a twin charge set up with the turbo and the super?

Here's some gauges

[BlakeNZ]

great work. Is the radiator custom built, or off the shelf "larger manual" unit?
Is there any way to front mount a cooler and NOT lose the air con core?

[fh2014]

I recon you could do it. There's still heaps of room there between grill and bumper. Piping would be the hardest bit, you'd have to shift that factory fusebox.

I only ditched AC as it didn't even fart when I tested the valve and I like to drive windows down anyway.

Yea cheers , radiator was something they had at redline, 50 something mm dual core as opposed to factory single core.

Factory one was Ali. This ones Ali just thicker. So hopefully better. With the Nissan i had, I noticed the cooling of the factory copper single core one was better than the alloy dual core. It wasn't till I got the custom built copper triple core that things stayed reaaal cool.

[fh2014]

currently building the throttle cable bracket, can anyone tell me if the second cable that goes to the trans is just a kickdown cable or does it control something else like line pressure

[BlakeNZ]

from my experience with the a340 trans( admittedly in RWD toyotas) the second cable does both. (unless it is the a340 from a jza80 RZ supra(twin turbo,1993 onwards), in which case there is no secondary cable, the line pressure is controlled by the ECU).

[fh2014]

bugger, im struggling to get it to hit both its fully open and fully closed limits, from what I can hear audibly anyway (there is a click at each end). will just have to experiment.

what might the symptoms of bad trans line pressure be so I know if ive got it wrong ?

edit: had a quick search, from what I could find it doesn't control timing of shifts at all. only line pressure. tighten for harder shifts, loosen for smoother shifts.. also on the harder side is better because the clutch packs aren't slipping for so long between shifts.

[BlakeNZ]

yes, sorry, The ECU uses throttle position and load to control the shifts I imagine. the "kickdown cable" ups the line pressure at appropriate times.

[fh2014]

Here's the clearance with the bumper back on. You could fmic with the AC still in.

[fh2014]

shes back on road and results are very promising. couldn't get egts higher that 710 deg C @ 10psi (9@inlet manifold) , and its almost if not as quick as the old terrano on 24 psi w 11mm fuel plunger very fun to drive. its still on the factory exhaust, still factory ecu and tune. im a bit dissapointed with the td27 now? guess theres no replacement for displacement, albeit 300cc. Well done toyota, the 1kz is quite a nice motor.

[Crash bandicoot]

I run full line pressure by default on my autos, run so much cooler provided ya don't mind the slight jolt between p/r/n and drive

[fh2014]

line pressure seems to be okay if a bit on the high side but im not concerned.

heres one for ya, the boost pressure is dropping pretty badly from 9ish psi to 4psi, only in second gear @ high rpms 2.5k-4k. doesnt seem to do it in any other gear. is this the result of the crap factory exhaust? wouldnt it do it in every gear due to engine airflow being the same?

[tweake]

heres one for ya, the boost pressure is dropping pretty badly from 9ish psi to 4psi, only in second gear @ high rpms 2.5k-4k. doesnt seem to do it in any other gear. is this the result of the crap factory exhaust? wouldnt it do it in every gear due to engine airflow being the same?

does it do it at steady rpm or only if you accelerate?
if its only when you accelerate, how quick is the acceleration after 2500 rpm compared to low rpm?
it may simply be the turbo is not responsive enough to supply air quick enough under high engine acceleration. if thats so then exhaust mods would help.

[fh2014]

yea its strange because at the moment its only mods really are an intercooler added, yet google returns nothing for a 1kzte dropping boost.

i think i can rule out that much pressure drop across the cooler, and will thoroughly check for leaks in the piping. ill have to keep trying things, take off intake piping, take off exhaust below dump, check waste-gate so on