igor is dead

[Jesda]

Toyota engine names. They basically let a cat walk all over the keyboard.

[themadscientist]

The junkyard really bent me over the barrel on the price and then wanted me to pay more for the piping and stock postage stamp-sized intercooler. Yeah, f*** you dude.
I'll rig something up. I already have an idea and that FD RX7 intercooler is $20.

Luckily my buddy let me borrow his truck to pick up the motor. He has a Suzuki Carry. OMFG is it cramped compared to my Hijet. They say my truck has an extra 4 inches of space and like your girlfriend would never admit to you, size matters!



He has tricked it out a bit with a ghetto stereo system with a DVD player and some nice 15s.


He turned some ammo boxes i gave him into some cool side boxes.


He also put a rear carrier on with a hitch and small electric winch to tow his waverunner which pumps out more power than both our trucks combined.


Alright, here it is in all its oily glory, the EF-DET 660cc 3 cylinder turbo.



Stock metal head gasket is pretty standard on these little guys as they have to push a bit of boost to compensate for their diminutive size.


You need it to contain the typhoon of air generated by the monster turbo!


How did I get it from the back of one truck into the bed of the other, I picked it up of course. It can't be more than 200lbs.



The turbo spins, but looks suspect. After I get it running I will be watching it carefully for signs it's blown a seal. All that oil has me worried. I heard it run, but revving at idle is nothing like running in a boost condition under a load.

I'm seeing some subtle differences, but nothing "aw f***!" worthy. Fingers crossed!

[Razi]

Wow that turbo and engine is tiny.
Would a CA18's T25 be too large and cause turbo lag?

[nissangirl74]

Nice Poe reference. One of my favorite poems ever. When you do the transplant, her new name should become "Lenore".

[themadscientist]

Well, I dug my NSR out of retirement, aired up the tires, slapped a new plug in it and took a scoot up to Daihatsu. The mechs over there are nice and are willing to entertain my strange ideas. They were able to confirm that the same fuel pump and radiator is used for all the EF engines. I will still be plumbing in a fuel pressure gauge and watching for dropping pressure and my water temps for anything out of the ordinary.

I then headed over to my storage and went through my boxes of crap and came back with a Go-Go Action pickup starter set. Sometimes being a terminal packrat has its advantages. I have another two of those blowoff valves, three of the big blue Greddy TVVCs and two other turbo timers in there somewhere. That's just the stuff I remember.

[Dattebayo]

This makes me want to own a glorified go-kart with a pickup bed on it. Too bad they don't sell this stuff here!

[Jesda]

I know of a guy on the Caddy forum who owned one of these mini trucks. I dont recall what brand but he dressed it up in camouflage.

[sultan]

This makes me want to own a glorified go-kart with a pickup bed on it. Too bad they don't sell this stuff here!

there's lots of these in the US as farm trucks, and they're actually road legal in certain states with restrictions (speed/certain roads).

oklahoma prohibits them from using interstate highways but they're legal on all other roads.

[ni_san]

hah man I miss little Kei trucks. It's funny because I'm probably the only one so far who knows what all of the names you've been shouting out have been lol. Upgarbage always had a bunch of tiny turbos there if you think the one you picked up won't work. Sad to see Igor's heart failed but now it can become... Frankenstigor o_O

[ni_san]

This looks like Awase?

[themadscientist]

No, down by Senega. They dumped dirt in the ocean and made land and then designed a logical community. You know the way it is here, there's a house, there's a tomb, there's a repair shop, there's a dude walking a bull, WTF? Not like that here. It's properly zoned, streets meet at 90 degree angles and so far no crazy neighbors walking around screaming. Wait, maybe I'm the crazy dude in the neighborhood.

This makes me want to own a glorified go-kart with a pickup bed on it. Too bad they don't sell this stuff here!

I don't see any legit-looking shops in MD, VA, WV or PA, but Mactown Minis is over in Illinois.
http://mactownminitrucks.homestead.com/ ... tions.html

They just sold this one. Not sure if it has been used to run from Roscoe or jump creeks.

[bigbadberry3]

This thread is so much better when you post pictures

[ni_san]

oh what the heck that's way off lol. They were actually in the process of making an island in Awase when I still lived there. No idea if they're done but that giant tunnel and the road that leads straight to that McDonalds intersection is done so they say. I did see a Kei truck here on base actually, a GOV to boot. Will your a/c work with the new engine? There + car with no a/c = death.

[themadscientist]

The bastard didn't give me the AC pump. I have reasonable confidence that my existing AC pump should work.

They did finish the tunnel. It dumps right out at what used to be Awase golf course. It's all open land now. I think they are talking about building another Jusco out there.

[Dattebayo]

I don't see any legit-looking shops in MD, VA, WV or PA, but Mactown Minis is over in Illinois.
http://mactownminitrucks.homestead.com/ ... tions.html

They just sold this one. Not sure if it has been used to run from Roscoe or jump creeks.

Well, it's just a pipe dream anyway. I'd have to get something that can handle pretty decent hills, can they do that alright?

[themadscientist]

I wouldn't put them in the same rank as a legit off-road truck, but they are reasonably tough.

[youtube]http://www.youtube.com/watch?v=Gq2jHeYzbgk[/youtube]

And for the record. My truck is by no means small. They have the Midget II. These guys drive them like I drive my HiJet!
[youtube]http://www.youtube.com/watch?v=TxPsFF0X ... re=related[/youtube]

[krash]

This makes me want to own a glorified go-kart with a pickup bed on it. Too bad they don't sell this stuff here!

I'm slowly developing a fetish too, thanks a lot mad.....

Honestly, theres no need for a pick-up unless you're towing stuff. I've been trying to get my dad to sell the dakota for a good condition 90's tacoma, but he likes his mopars too much.....

[themadscientist]

Stage one was performed a few days ago. These engines are tucked up in there so bad there is probably a circle of hell where the damned must tighten and loosen the manifold bolts for eternity. Being a clever fella I thought it would be wise to replace some stuff before swapping it.

This motor is covered with oil. I heard it run, it sounded fine, but that oil came from somewhere. I can't really be sure because it's everywhere so I went after the usual suspects. The timing belt has been changed, but I don't know when so it's going to get done. Oh, oil.



Normally I stick a socket on the flywheel and wedge it against a bolt, but I couldn't do that so i came up with plan B.



It's a short little belt and thankfully cheap. There's the timing mark I was looking for.



It only has one sprocket so there must be a countergear in the head running the two cams.



I replaced the cam and the front and rear main seals. There's the cam angle sensor.



I had to beat the water pump out. I hope I didn't crack anything.
Seriously, the guy who designed this thing needs a b**** slap.



Belt swapped and seals done.



I changed the spark plugs too. These are weird.



Coil on plug on both engines. This one has a cracked coil. I need to confirm my suspicion that the SOHC uses the same coils so i might have back ups.

[float_6969]

LOL, this is gonna be a riot when it's done.

[themadscientist]

I didn't want to do the swap in the driveway so I called a tow truck to take me to the on-base auto hobby shop. The f*** charged me $122! I was pissed, but I got it there.



I unhooked all the connections and dropped the engine to the floor. I tried to slide it out, but it hit the diff.



I elicited the help of someone else to pull the engine out while I clean and jerked the truck.



The engine pulled I set to work swapping the manual transmission and transfer case onto the formerly automatic new engine.



I tried to buy a pilot bushing to put in the automatic crank, but they told me there was none. it sounded odd and it is, but it's true.



The flexplate and flywheel bolts are the same, weird.



Timing is shot through a hole in the bellhousing. The marker for the automatic and manuals are different so you need to switch it.

[themadscientist]

Now, the Atrai has a lot of similarities, but while the mounts are interchangeable, the crossmembers will not bolt up to the Hijet so I had to switch it.



I opted to put the engine up by itself to make it more manageable.



Kim was nice enough to run the jack while I balanced the engine precariously on it risking my fingers at every turn.



Putting on the transmission was a straight b****! It was worse than the GT-R unit.



I tried to pull it on by tightening the bolts, but it would not go so older, wiser Mad took a step back and tried to figure out why. Here it is. There is a dowel on the transmission, but apparently there is not one on an automatic; it's on the engine. I had two dowels butting heads. I really did not want to pull that transmission back off so I rotated it until the dowel lined up with a bolt hole and drove it out and into the hole with a punch. It's still in there. I need to get in there with a magnet or some gum on a stick so I can fire that last bolt on.

[themadscientist]

Today's work is done. The mission was to get the engines physically switched and I finished that.




The muffler will need to be modified. It's too long.



No worries.



Now, there was no damned way I was paying those greedy f*** that blood money again to get the truck home so I called JAF, the Japanese AAA. Now, they couldn't come on base so I pushed the truck out the gate.
Also, they respond to broken down vehicles, not what I was doing. Kim bought me some clean clothes and I changed over for my time on stage where I told the guy it just broke down.



When he asked about the other engine I just said I had to get another to replace the broken one. 10% true.



Now the hookup and first 15KM are free. It was 16.3 to the casa. Old boy said "you took a longer route than I would have, it probably would have been 15KM, f*** it." I thanked him and gave him a can of the holy elixir, RC cola for the road. I had the wife explain this is what poor people drink.

Igor is swapped and back in the driveway. I will attack it next week hooking up wiring, plumbing, and figuring out an intercooler and piping solution.

[Razi]

Sneaky man.

[themadscientist]

Alright. I spent a little time hooking up some stuff. I have found all the connections for vacuum lines save one, the line from the boost control solenoid. I suspect it goes to the airbox, a part I don't have.



The coolant inlet and outlets for the engine are different. EF-SE from Hijet.



EF-DET from Atrai. The top radiator hose from the Hijet just reaches, but the lower doesn't make it.



I will have to look at the Atrai radiator to see if the inlet and outlet are in the same spots as the hijet. If so, off-the-shelf Atrai hoses will work. The two coolant lines for the turbo are a mystery. I suspect they feed into the aforementioned hoses.




See that plug? That must be for the oxygen sensor. I need that outlet elbow.

I have reviewed the wiring schematics and while there are a few differences, the pins are in the same locations. Any differences are active pins on the turbo engine harness that are not on the non turbo, but for things like ABS and a rear window defroster. f*** me if doesn't look like plug and play.

Houston, we have a problem!

See how much longer the old harness is compared to the new one? That box under the dash is the CPU and this harness isn't even close to reaching it!




Cut, extend, solder, shrink wrap, repeat....

The real pisser is the AC pump. Yes, I still have AC in this truck and Intend to keep it! The bolt on the back tab snapped off and I can't get to it to extract it without removing the pump. I kept the system sealed hoping to just put it on the new engine. That, plus the fact that the two engines' brackets are not the same is a bad thing.

The brackets could be different because the pumps are different. That's not a problem since the pump doesn't care what it's on and I can retain my pump after I extract the broken bolt, IF that's the only reason they are different.

The two engines have decidedly different intake manifolds and there is a possibility the brackets differ to provide clearance. If that is the case I may be forced to buy the turbo AC pump and hope the lines match up, more money.

[raremotive]

The adventure continues.

[themadscientist]

WTF is wrong with me. Loaded question, yes, but worth asking. I don't even have this thing running again and I find myself researching turbos that might fit this 660. Apparently, Mitsubishi Pajeros carry a TD04-09 turbo that might go on with an adaptor plate. It doesn't look like it pushes much more air than this dinky IHI, though.



It might be a nice proof of concept, though to make the plate and run the plumbing and later step up to a TD04H-15G




Because I don't have the factory intercooler I'm going to have to fab a set up and you know it's not going to be "adequate." I'll probably try to hang some big thing under the side of the truck and be all laggy. This turbo looks like it will support high pressures and 100hp, but the outlet is the size of a garden hose!

DAMN YOU GOOGLE! Stop "helping" me...

http://www.kc-technica.com/tuning/s320g ... turbo.html



I think I better start rounding up extra transmissions.

[Ozzie]

Hurrah for impromptu build threads!

[Razi]

Get it running already!
If you want easy power, just up the boost. :P

[float_6969]

TMS has never just installed something in his entire life. I think he has automotive ADHD.

[themadscientist]

Hey!
What?