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2jz swapping my clean kouki after 16 years
After 16 years of ownership I did finally decide to bite the bullet. My car is a very good example of an s-chassis and the one thing that always kind of let it down was the engine bay- granted it was a pretty good KA-T setup, just tired and not up to par with the rest of the car. It was time for something else. A single turbo 2jz setup with paint matched bay and quality components should really help with that. Anyone who's been on here a while has probably seen pictures of my car "before", but here's a little refresher.
https://i.imgur.com/5RGewee.jpg https://i.imgur.com/1ahTCBj.jpg https://i.imgur.com/CP2S9QT.jpg So I'm a pretty good ways into the swap at this point. The goal is to use quality parts and fabricate what I could myself- the intercooler, exhaust, charge pipes, etc. The engine is a jdm non vvti, stock internals, freshened up with studs and HG, BC 264 cams springs and retainers, new waterpump and timing components. Stock r154 trans, light flywheel, aluminum DS. Here's a few photos of the engine tear down and refresh. The engine covers will be painted closer to the end. https://i.imgur.com/dNpZP83.jpg https://i.imgur.com/cbR56Oj.jpg https://i.imgur.com/ImAVmIQ.jpg https://i.imgur.com/pnhosRE.jpg https://i.imgur.com/4eK95XU.jpg https://i.imgur.com/zd28Cwu.jpg https://i.imgur.com/qi4lNKY.jpg https://i.imgur.com/qTWs83A.jpg https://i.imgur.com/foQF6zp.jpg https://i.imgur.com/LyhqHBv.jpg https://i.imgur.com/1sVpTYe.jpg https://i.imgur.com/W7EMiv4.jpg made a water rail without all the unnecessary nipples pulled the ka https://i.imgur.com/BvRpMzk.jpg https://i.imgur.com/rBMkUuL.jpg Next, I mock up the tucked radiator/condenser/IC core and trim a few areas, as well as patch the battery tray and corresponding area behind the DS headlight. https://i.imgur.com/6ik98fL.jpg https://i.imgur.com/2tkWQtz.jpg https://i.imgur.com/f1SmCPA.jpg https://i.imgur.com/lJzo4UM.jpg https://i.imgur.com/zlf1OWi.jpg https://i.imgur.com/xldZGzt.jpg https://i.imgur.com/dZeMWHP.jpg https://i.imgur.com/sDMJwm5.jpg https://i.imgur.com/cWoXmVW.jpg https://i.imgur.com/6FjJoEl.jpg https://i.imgur.com/hssyPPf.jpg https://i.imgur.com/g460p1E.jpg Up next painting the bay and dropping it in. Sorry if some of the vertical images are huge- trying to fix that. |
Originally I had planned to paint the bay gloss black since I may end up changing the color of the car in years to come, but after some deliberation green would really just look way better so green it is.
https://i.imgur.com/WTs0X0x.jpg https://i.imgur.com/p44uH8l.jpg https://i.imgur.com/MreBr5K.jpg https://i.imgur.com/s4aLVVe.jpg https://i.imgur.com/Rl9wrVF.jpg https://i.imgur.com/blEmDHS.jpg With clearance of the intake manifold being a known issue I installed chasebays lines and a new z32 master, plus they just look way better. |
Looks good but you should've hammered out some clearance on the transmission tunnel before paint. Now you're going to end up hammering fresh paint. Ask me how I know. :cry:
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Maybe I’m way too anal, but I padded the hell out of everything in preparation to setting the engine in.
https://i.imgur.com/zM9tZoB.jpg https://i.imgur.com/270ot3F.jpg Success! https://i.imgur.com/qzXdq2I.jpg https://i.imgur.com/MmKNz2D.jpg https://i.imgur.com/GDEmRi3.jpg https://i.imgur.com/hiVbZBu.jpg https://i.imgur.com/jK6f0XO.jpg https://i.imgur.com/jNKMjeM.jpg https://i.imgur.com/y9g7w9f.jpg The excessive extended shifter housing still didn’t land the shifter exactly where I’d like it but it’s good enough- You’d think with the same company’s mounts and everything it would be a little more on point but it’s not. The engine could go back further IF I modified the trans mount, which I really don’t care to do. The upside is I have plenty of hood clearance and the extra room between the bell housing and tunnel makes it nice if and when I have starter problems. |
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Beautiful car and build!
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In for this build!!
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Following along. Clean car ��
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wow impressive bro. been following you since and great choice of motor swap
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Mounting the radiator, intercooler, and condenser. I know the Derale shroud is massively thick, but even so there is enough clearance to service the drive belt after it is installed. I want to be sure this thing stays cool. Cooling problems are always caused by people using cheap single pass radiators and mediocre fans.
https://i.imgur.com/03bcGDm.jpg https://i.imgur.com/DZwZA8a.jpg?1 https://i.imgur.com/65M1OBG.jpg |
^^ what are the radiator specs, thanks.
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Next I built a new fuel system. You saw in a previous photo I am using a radium rail and ID 1050x injectors. I installed a walbro single 525 in the tank along with 8an and 6an bulkhead fittings into the factory bulkhead (not pictured). I ran the lines on the drivers side and 3d printed some brackets to hold the lines and inline filter up nice and tidy. Pictured is another bracket I designed to hold the fuel and clutch line where they come up into the engine bay where a factory heat shield originally bolted.
https://i.imgur.com/x9x3yqF.jpg https://i.imgur.com/Ws1unSY.jpg https://i.imgur.com/BFMUc3X.jpg Feed right off the back of the rail with a 8an banjo fitting https://i.imgur.com/l0koeJ1.jpg return off the front of the rail to the FPR- I?m not completely satisfied with this routing and I may change it. |
what is the spec on that condenser and what engine and trans u mount thanks ? loving this build
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I have always been a huge fan of your car man! Love the stock styling and cleanlyness of it. Can't wait to see the finished product once the swap is complete!
Cameron |
Looking good. Cant wait to see final results
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Thanks y'all. Not sure on the condenser, I figured it out so long ago and don't have the box anymore. It's a generic one with integrated drier, approximately the size of the radiator (23x13)
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Here?s about where we?re caught up, building the intercooler and charge pipes. It?s pretty straight forward so I will let the pictures explain everything. I haven?t seen many people do a back door intercooler setup on s-chassis, but It?s so neat and tidy, and with the narrower radiator I am able to go that route. The o ring?d male/female ferrules and clamps dress it up over standard silicone couplers and are hopefully less likely to leak.
https://i.imgur.com/ElJvU7M.jpg https://i.imgur.com/kgJcN4H.jpg https://i.imgur.com/oR9lUTq.jpg https://i.imgur.com/qBhxeqT.jpg https://i.imgur.com/HXtmtDL.jpg https://i.imgur.com/EKqSlbo.jpg https://i.imgur.com/mRkm5Qn.jpg https://i.imgur.com/M8XfRXD.jpg?2 |
Looking good so far.
I've seriously contemplated ditching my KA-T in favor of something smoother and better sounding, like a JZ. I'm interested in seeing how you will compare the two setups when it's all done. |
I'm happy you already stated the engine covers are getting painted closer to the end. Everything is way to nice for them in their current state. Keep it up!. This build is awesome
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Shit this is rad. Dude over here making his own intercooler. Assuming you are going to maintain ac and heat with this beaut?
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Subscribed for more car porn
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Wow man looks great. Keep it up
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Thanks! Yeah the plan is to have heat & a/c and I plan to do an electric power steering conversion as well.
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Spencer, Nice to see you've held onto it for so long and it still in very good shape
Enjoying the current refresh and upgrades |
Building the downpipe. I will be recirc'ing the WG dump tube back into the downpipe but I need to let that marinate in my head to find the best routing for that.
https://i.imgur.com/GaEwics.jpg https://i.imgur.com/XakppNv.jpg https://i.imgur.com/HjVh9qH.jpg https://i.imgur.com/Oqzimjs.jpg https://i.imgur.com/1W57Jct.jpg https://i.imgur.com/2flq0fy.jpg Since I'm doing the opposite of what most people do (keep A/C but delete hydraulic power steering in favor of electric PS) I needed to retain the factory belt routing but just shorten it up slightly. I built an idler pulley setup that uses the cast iron PS pump bracket but uses a much smaller pulley and sits lower for better cold pipe clearance and a tidier appearance. https://i.imgur.com/Ru771zT.jpg https://i.imgur.com/pyQtv85.jpg https://i.imgur.com/TpiBWQl.jpg https://i.imgur.com/6FloQ1c.jpg charge pipes are next |
wrapped up the downpipe and WG recirc pipe.
https://i.imgur.com/LWYPuB9.jpg Here's the intercooler piping. I decided to weld all the ferrules for the ends of the pipes from the inside for a cleaner look. https://i.imgur.com/ReSDTOB.jpg https://i.imgur.com/ck5AHaC.jpg a 3" ferrule on a 2.75" throttle body means I had to sandwich a small piece of 3" od tubing between the ferrule and throttle body but it's hard to see unless you know to look for it. https://i.imgur.com/gg7SeVF.jpg https://i.imgur.com/7uruXnB.jpg https://i.imgur.com/4JprXSv.jpg https://i.imgur.com/XEQnEgf.jpg https://i.imgur.com/V6axeYy.jpg https://i.imgur.com/gs1y2UY.jpg https://i.imgur.com/VrbDjVu.jpg https://i.imgur.com/RhGbtgo.jpg https://i.imgur.com/XEH7gzo.jpg https://i.imgur.com/8zU9xLQ.jpg https://i.imgur.com/CDUJAoi.jpg https://i.imgur.com/bOJrLrH.jpg https://i.imgur.com/Pyz9IJv.jpg |
Wow that looks crazy clean. Great idea welding on the inside of those couplers
Sent from my iPhone using Tapatalk Pro |
Thanks Mike!
DC integra radiator hoses? Ok. https://i.imgur.com/FzvMvND.jpg https://i.imgur.com/LLobk8A.jpg |
Cerakoted the exhaust parts. This was my first time using this product, shot with the "glacier black" color.
https://i.imgur.com/kYwbY1a.jpg https://i.imgur.com/qUfJcSh.jpg https://i.imgur.com/lkv5O5S.jpg https://i.imgur.com/Lucwi8D.jpg I know the valve covers and coil cover look horrible! I'm getting to that soon. I also 3d printed a small din housing to hold the AEM gauges. The bulky bezels look so out of place in a 90s car IMO. https://i.imgur.com/b3TsQeu.jpg https://i.imgur.com/76JQrdw.jpg https://i.imgur.com/IRrRYjK.jpg https://i.imgur.com/CcpBrv8.jpg The sound quality from the factory tape deck is not great, but I love the look, and for how much I use the car this should be just fine. I decided to convert it to bluetooth/hands free by hijacking the L and R channels from the tape deck. https://i.imgur.com/YTIQDIN.jpg https://i.imgur.com/h95HlPL.jpg |
Looks good man , Glad to see your build still alive and kicking!
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Man, that bluetooth mod. The little things that make builds awesome.
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Wow, loving this build! The color is outstanding too!
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Thanks! Slowly checking off all the little boxes I guess!
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this is so cool, such attention to detail, love it
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That triple gauge din is sweet! I have been trying to find an OEM-esque looking one myself. Any STLs or how on that??
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If you have a way to print it I can send you the file for each of the two pieces. You will probably have to do some modification especially if you're not using AEM gauges.
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wow!! amazing!!
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This is incredible! Such a great attention to all of the little details.
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It's been a minute since I posted an update here. I'm slowly going down the list. First thing to do was build a catch can. I was inspired by the dukefab design but wanted mine to also cover the wiper motor since it's ugly. I 3d printed a little filter/housing with uni filter mesh instead of a "sandwich" design like I've seen on others. Here's what I came up with
https://i.imgur.com/m041GEr.jpg https://i.imgur.com/8DdrJZT.jpg https://i.imgur.com/PT9etzN.jpg https://i.imgur.com/CoG21Xc.jpg I'm thinking about powder coating it wrinkle black. Raw looks okay too I suppose, other than the marks left from the brake. |
Next I went ahead and cut back the inlet on the turbo and welded a 4" ferrule to use the same style clamp as the charge pipes. I should easily be able to swap between a custom turbo screen or an air intake tube/filter.
https://i.imgur.com/61qEFSD.jpg Next it was finally time to deal with those nasty valve covers. I stripped and painted them gloss black. https://i.imgur.com/GtNB4SQ.jpg https://i.imgur.com/mH8mA3C.jpg https://i.imgur.com/ImBjRwF.jpg the radium fittings are a must to keep things tidy and away from the heat of the manifold and turbo https://i.imgur.com/hx8gGLG.jpg https://i.imgur.com/yF4bGeS.jpg https://i.imgur.com/VBjuoT5.jpg |
Finally it was time to do something special with the coil pack cover. I've dipped a lot of valve covers and interior trim etc. in the past but this was still challenging to get right given the shape and size, and all the holes. There are imperfections here and there but overall I'm pleased.
https://i.imgur.com/pUqMTS3.jpg Matches my bike I built a while back ;) https://i.imgur.com/VLRy6Gi.jpg?1 |
Installed the WS harness/infinity 506 and painted the throttle body and compressor housing. I'm going to make some brackets to hold the harness up better against the firewall. I just got all my AC fittings so that's probably the next step.
https://i.imgur.com/QEU2AxX.jpg |
wow man... just when you think it couldn't get better. Fire build! That catch can is dope man
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Very well done work and creative. The engine and bay are looking tidy.
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that setup looks killer, I ALMOST would have done color matched green valve covers.
Curious as to what the turbo/exhaust manifold setup is you're using? |
Thanks guys. I thought for half a second about doing green valve covers but I was afraid it might be too much. Turbo is a BW 66mm .91 divided manifold is XS-power. I needed to do some finessing with the head flange but otherwise the quality is not half bad.
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Very aesthetic! You had a really cool looking KA-T setup as well. Looking forward to seeing the rest of this.
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The wood grain valve cover compliments the dark green engine bay nicely. Well done.
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Thanks!
Have been working on this a little here and there still. I tried a few different throttle cables and settled on just using the OEM s14 cable. I routed the excess under the manifold and made a little bracket to attach it near the throttle body https://i.imgur.com/qFAKs2X.jpg https://i.imgur.com/78dsJt5.jpg When I painted the car about 12 years ago I didn't do the most amazing job I'll be honest. Not that it's a "20 footer" but I should have taken the time to paint match all the door shuts, trunk shut, etc. With the fenders off I took it upon myself to paint the area inside so it looks nice and fresh like everything else. Eventually I will repaint the whole car but it looks good enough and how often do you really have your doors and trunk open? https://i.imgur.com/RU6DesG.jpg https://i.imgur.com/szM4Xhl.jpg I threw the lights on for the heck of it too. Catch can done in wrinkle black powder https://i.imgur.com/ksBVIt8.jpg https://i.imgur.com/8vX1WiB.jpg https://i.imgur.com/DmAQ1hx.jpg I repainted the wiper cowl, wiper arms, and wiper arm caps with SEM trim black while they were off too. https://i.imgur.com/xz3DKH9.jpg P2m hood strut kit installed The bottom of the hood needs a good cleaning. That white crap around the washer squirters is just clearcoat residue from color sanding the hood. |
Exhaust is now complete as well. I want it to be LOUD but I threw in one bottle resonator to hopefully smooth the exhaust note out just a little bit. IMO JZ's definitely sound best with a big ass 4" pipe and as few bends as possible.
https://i.imgur.com/b8bPQZX.jpg https://i.imgur.com/Qa0AdMG.jpg (don't worry this is a joke) :D https://i.imgur.com/HLLkRoL.jpg https://i.imgur.com/Kx7NON9.jpg https://i.imgur.com/EVCME62.jpg https://i.imgur.com/lkVGxYw.jpg https://i.imgur.com/RPMlpwr.jpg |
That exhaust turned out super slick.
Off topic - Where in SC do you live? |
Thanks! I'm technically in SC but more or less Charlotte, NC.
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this thing is sex
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Made the tucked AC lines and an intake pipe. Started the car as well.
https://i.imgur.com/TNrfruh.jpg adapting standard size reduced barrier fittings to factory firewall and JZ compressor fittings https://i.imgur.com/nd1ZvKP.jpg https://i.imgur.com/CVwNKgW.jpg https://i.imgur.com/JEFT3oN.jpg https://i.imgur.com/y44xRN2.jpg had to make this funky piece to integrate the factory pressure switch in the system https://i.imgur.com/TEATuAG.jpg mocking up hoses https://i.imgur.com/GeTbdGX.jpg hoses ready for crimping https://i.imgur.com/JeFDBgr.jpg back from the crimper https://i.imgur.com/1rqXEBo.jpg https://i.imgur.com/uVcbkIu.jpg https://i.imgur.com/B04gHsC.jpg I didn't take photos of how I fab'd the intake tube but here's a pretty pic after making it and polishing it up. pretty boring but there you go. Will update soon once I get it idling and coolant bled etc. |
Love the build! I just started mine again after many years, and feeling it move under it's own power again was an amazing feeling.
I am interested in the cooler/A/C setup details though. Did you have to order a customer radiator, or did you just get one of their dual pass SBC radiators and modify the fill point? Your welding skills definitely give you a leg up there. As for the A/C setup, I know you said you don't remember the condenser, but did you have to add your own drier/accumulator in the system or was it built into your condenser? If so, where did you end up adding that? Assuming you just used the Aristo compressor with the factory 240 pressure sensor? |
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holy fuck!! i just came on myself!!
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Very nice build!
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Thanks y'all. Not a whole lot of progress lately. I did install new coilovers and raised the car to an old man kind of height. I want to enjoy driving it when I drive it not have to clench my butt cheeks over every pothole I see.
https://i.imgur.com/14IROFS.jpg https://i.imgur.com/4sTLzUR.jpg https://i.imgur.com/TtUmQ3O.jpg https://i.imgur.com/70Kqx5w.jpg |
Don't be ashamed by a normal ride height. Car is awesome!
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You know when your older then pc/ac and comfy is needed lol. Build looks great
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Looks like after running it a bit more one or both of the cam seals have failed. I had used a non OEM seal on one side since I damaged an OEM seal during install. I guess that came back to bite me in the ass so I have to address this asap :rolleyes: I knew I should have waited and got an actual toyota seal. |
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I personally followed this write up and had great results.
https://www.supraforums.com/threads/...-black.674305/ I've owned far too many S-chassis running aftermarket carpets and they all fit bad. No where near as nice as an OEM one. |
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On the other note, it didn?t like my back seat. It made the fabric hard and feel cheap. I have a roll bar now so it didn?t matter. I?m sure if I went with rit dye for the back seat it would have been better. |
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I'm surprised your carpets are worthy of a dye. Mine are trashed and have a huge hole near the pedals so I'm gonna give stockinteriors a shot. A few guys on here have had good results: #/f/showthread.php?t=654618
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I have the car running and driving pretty well on a base tune now. I am putting miles on it so I can have it street/dyno tuned in the next couple of weeks. No real complaints or issues at all which is surprising. The 4" exhaust is epic in sound and not obnoxiously loud- I will get a driving video.
When I first drove the car I quickly realized how awful no power steering is so I took it upon myself to do the electric PS colum conversion using a column/motor from a chevy equinox as a donor and cut and spliced it with the s14 column. I ordered a steering controller with an adjustable dial and wired it up. The sweet spot tends to be just under full asist. I am happy to do a more in depth write up on another part of zilvia if anyone else is interested in doing this conversion too. https://i.imgur.com/1SZFTBd.jpg https://i.imgur.com/fdzzMl8.jpg If you're part of the s14 owners group on FB I posted a demonstration of the power assist in action there. Not sure if it's visible otherwise. https://www.facebook.com/11829797/vi...08240625163029 https://i.imgur.com/gxcnFPd.jpg |
Can't see the vid but definitely interested in the EPS conversion.
Also how much did it cost all said and done? |
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steering controller with potentiometer dial $65 HERE ON EBAY 8 gauge wire and 80 amp fuse/holder/terminals $40 spare s14 column (Made things easier but not necessary) $90 total $270 |
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