Builds Recently acquired locked 94 build

[swankstar]

After much headache over the harness, I decided to just start from scratch and build a completely new harness for the large ECM connector (60 pin), and get prepared to do a new harness from scratch for the small one (50 pin). To make it easy to pull the engine, I figured out how to route and connect everything so the 50 pin harness gets disconnected and stays with the vehicle, and added one 8 pin Deutsch junction to the 60 pin harness so those 8 wires can stay with the engine and the 60 pin harness doesn't get disconnected.

Made five harness/ecm support pieces, four of which can be seen in these pics:

any guesses what this part is for? printed a bunch but only one fits on the rig

 

[swankstar]

Got the "build-a-bear" version of upgraded turbo, all these parts in a box. Basically stock turbo from a 06/07 truck I think, but with a larger compressor wheel.

The larger compressor wheel was something I had forgotten about when assembling until it got time to torque the wheel on to the shaft. Snugged it down finger tight and then, no spinny. Looks at it a bit before realizing the wheel was sitting ON TOP OF the center section (pic below), where instead, the exit surface of the wheel should be flush with the center section. Off to the lathe for a couple cuts to get the wheel down inside.

With that done, went together real nice.

We'll see how long the 500$ turbo lasts

 

[Will Van]

any guesses what this part is for? printed a bunch but only one fits on the rig

View attachment 3728597

Accelerator cable?

 

[Will Van]

To make it easy to pull the engine, I figured out how to route and connect everything so the 50 pin harness gets disconnected and stays with the vehicle, and added one 8 pin Deutsch junction to the 60 pin harness so those 8 wires can stay with the engine and the 60 pin harness doesn't get disconnected.

I love this idea. Fantastic work.

 

[swankstar]

Accelerator cable?

Bingo! Was looking at how I was going to get the drive by wire pedal through the firewall after realizing my bulkhead connector from before was full (and not wanting to add another) when I got under the dash and literally had the light shine on me, from the hole where the 1fz accel cable went through. Printed this little guy with built in strain relief on the corners and a spot to put a piece of HD heat shrink on the outside to seal it up. OBD2, accel pedal wiring, and ign hot all fit through it.

 

[swankstar]

 

[swankstar]

Bad picture because spent the last 800 hours straight working on this thing with lots of help. Got it running and driving. Will report back later.

 

[swankstar]

how much gunk was left on the counter after disassembly (AFTER thorough cleaning before putting parts on the counter)

View attachment 3313867


you can see the difference between the two connectors in this photo. original on right, two large blades in line with each other, new one on left, two smaller blades perpendicular to each other. I KNEW I had seen a connector like this before, laying around the shop, but couldn't find it.

View attachment 3313868

close of up 94 connector

View attachment 3313869

close up of new connector

View attachment 3313870

went to junkyard, did some digging, found a connector that would work from a random fan. pretty sure this is simply a "fan connector" that has wide applications.

View attachment 3313871

Can finally confirm this new fan works, but I don't know how well yet. I figured out much later the new fan is for non-AC vehicles and you can see it doesn't have the second, shorter set of fins.

 

[swankstar]

Had rig on the lift today for 500 mile oil change, 500 mile check on the bbk, figuring out some of the heater hose routing, and looking at how I'm going to approach exhaust. Figured I'd add some parts while I had everything apart, including the @Outsane "never lost" brake bleeder caps, super stoked on those.

 

[Outsane]

Nose hose routing

 

[swankstar]

Last weekend decided to clean up the old engine harness/engine bay a little bit since I have almost everything working the way I want it now.

This bundle of joy has been stuffed in the fender well since before the 4bt part of this adventure and had a bunch of oil leaked on it, etc and was a grimy mess. Finally time to peel it apart and sort out what stays and what goes.

First step is get everything in one place, then pull out the ecm and start tracing stuff.

Midway through.

This is the pile of what I removed that is all 1fz related and unnecessary moving forward.

Got it all straightened out so I can wrap it up and store for connectors and pins if needed.

 

[FMC80]

Last weekend decided to clean up the old engine harness/engine bay a little bit since I have almost everything working the way I want it now.

This bundle of joy has been stuffed in the fender well since before the 4bt part of this adventure and had a bunch of oil leaked on it, etc and was a grimy mess. Finally time to peel it apart and sort out what stays and what goes.

View attachment 3762787

First step is get everything in one place, then pull out the ecm and start tracing stuff.

View attachment 3762788

Midway through.

View attachment 3762790

This is the pile of what I removed that is all 1fz related and unnecessary moving forward.

View attachment 3762791

Got it all straightened out so I can wrap it up and store for connectors and pins if needed.

View attachment 3762792

So much patience and solid work!

 

[swankstar]

Nose hose routing

all kinds of nose hose around here...

 

[swankstar]

So much patience and solid work!

thank you

 

[swankstar]

Decided to finally add provision for boost gauge yesterday, requiring removal of fuel rail. Intake plate has a nice cast in boss that looked like it would work perfectly to tap for it. Started a 3d print drill jig but once I hit go realized it wouldn’t be done for 6+ hours so just free handed this one, worked out just fine.

All buttoned back up, wasn’t too bad. Nice having boost gauge again. The wutang whistle seems to offer good performance so far. Gives between 5ish psi cruising 65-75mph, and 10ish on an incline. Stomped on it and hit 30 almost instantly.

Looking forward to getting intercooler sorted to compare performance and egt. Have never done a before/after IC comparison on same rig so it’ll be interesting.

 

[Outsane]

30 psi! Very nice

 

[swankstar]

30 psi! Very nice

And it was still climbing too

 

[swankstar]

Just picked one of these up, plumbs into the coolant system, runs off the diesel in the tank. Burns said diesel and transfers the heat to the coolant system and circulates it through the heater core. When it's burning, you have the option of triggering the HVAC system and running the defrost/heat. End result is it heats up the engine and the interior. Good for cold weather camping.

Now I just need to find a place to put it.

 

[Outsane]

Dick butt approved

 

[Kief]

Excellent work. My rig would be much better off with hydroboost..