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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 15 April 2004 21:19
 
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The rear half-shafts off the ST185 GT-Four mated up to the diff and my rear wheels without incident.  It needs to have the stabilising bracket re-attached (welded) to the chassis rails, as the mounting points for the GT-Four's rear diff are a bit different. This won't be an issue however. Today it will be off the ramps and back on terra-firma for the time being, until the exhaust gets made up for it. In the meantime, the BOV was mated up via the medium-sized pipe on the TMIC. Looks cool.  I'll get some more photos of it tonight. All the flanges are on the exhaust components, all I need is the main pipe sections to join them all up. I'll have to have the split or "Y" in the exhaust pipe before the rear diff, so it goes directly under the two lower control arm mounts which will fit the pipe in very snugly. It's coming together well... I just hope this train of good luck keeps on rolling. 
Cheers.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 19 April 2004 22:20
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The rear differential bolted up with a little modification being required (mounting bracketry), and she's now off the ramps. The LSD is somewhat heavier than the RAV4 rear diff.  The tailpipes were located and temporarily mounted on the RAV4 to see which way they'd fit best. Straight out like a normal exhaust isn't an option, the canon's are too fat, and hit the body instead. They might have to be tilted outward about 30° each from centre to line up the pipes from under the diff.
Here's how they look 'loose'...
The engine was dropped in on it's mounts today, no fitting issues here either. Only problems I can foresee are: 1) the turbo might come too close to the thermatic fans (this can be overcome), and 2) the throttle body runners will most likely come into contact with the clutch master cylinder. Also the runners might need slight modifying so as not to come into contact with the firewall.
Other than that, the engine sits rather nicely in the bay, and the TMIC comes about level with the bracing of the bonnet when it's closed. The throttle body is my next concern, as I don't know how this sits in relation to the firewall, or how high it will be in relation to the bonnet. 
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Location:
Sydney, Shire
Registered:
April 2004
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 21 April 2004 11:56
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i live in the engadine ...
im surprised i havnt seen it around
im sure i would of noticed it...
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 21 April 2004 12:18
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I usually don't go by Engadine, but the car's being rebuilt near there. At least the engine is in the car now, all it needs is the undercarriage to be sorted out (link up the half-shafts to the gearbox), the throttle body will need modifications, as will the location of the turbo. There's still a few things to sort out before she gets a kick-over.
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Location:
Sydney, Shire
Registered:
April 2004
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 21 April 2004 14:15
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where is she gettin build atm?
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 21 April 2004 14:17
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Not at a 'shop', if that's what ya thinkin'...  No a mate of mine is doing the dirty work on my beastie.
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Location:
Sydney, Shire
Registered:
April 2004
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 21 April 2004 14:21
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haha o ok
well i might see it round in the future sometime
laterz
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Location:
Melbourne
Registered:
October 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 22 April 2004 14:41
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I'm following this with much anticipation...
In other words. HURRY Up hehehe
man this car is gonna be sooo awesome when its done...
good luck..
how long now?
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Location:
Richmond NSW
Registered:
September 2003
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 28 April 2004 14:29
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I can't believe you got that all out in one breath... Use punctuation dude.
Ok before I go disappointing anyone, how many RAV4's have you seen with 'wanker' canons on them? Out of all the ones I've seen up and down the east coast, I can put about two to memory. Agreed, they don't have a good standing in relation to some modifiers *in general*, but fair suck... the RAV4 deserves this. Besides I couldn't go straight pipes, not off a turbo. The undercarriage isn't shaped as simple as that. The 3" pipe still has to get under the rear diff and still clear 4" off the ground to be legal. THEN after that, it has to take the route that has least back-pressure - having the canons on angles is the only way it can be done. The main body of those canons is 6" across each... this leaves bugger-all room to play with in the rear to position them right before they are fixed up to the main pipe.
How long now? How long is a piece of string.... hopefully not that long now, but I'm still finding stumbling blocks. #1) The engine is sitting a LOT lower in the engine bay than first thought, posing problems. One of these is where the turbo sits in relation to where the thermo fans are. One of these is ok where it sits (which is the Aircon), but the other is going to hit the turbo unless I can find something not quite as deep. #2) The dump pipe can't be used where it currently sits... there's not enough room for it to bolt up to the main turbo body from underneath. The solution to this is to make up a new dump pipe using the rear flange adapter, and going from there. I dare say it will probably be about 3.5" - 4" wide and the hi-flow cat will be mounted underneath instead of in front of the engine.
One positive to come out of this is that the intercooler isn't anywhere near as high as I first thought it might be, so a Cusco strut bar is still on the cards. 
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 29 April 2004 14:18
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Got a thermo-fan from SC tonight, not real flash but it will get me out of trouble. No one will see this either.  It's just a basic 12" dia. 12-volt fan with a grille and clips. Fairly simple. This will get fitted up tomorrow, while another slave cylinder is sourced. The RAV4 cylinder is too big for the job, getting in the way of the throttle body runners. I'm guessing something like a Nissan 200SX slave cylinder would do, it's smaller at least. Only effect I'd feel is the clutch depth. Nothing I can't get used to.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 05 May 2004 08:40
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Bought a second-hand clutch MASTER cylinder (not slave) from an older Subaru I think... Doesn't matter. It's less than the required 70mm that's needed for it to fit up nice. It can be modified, but the RAV4 cylinder can't - it's way too long (100mm).
In the process of exploding a wiring diagram so this baby can kick over and not short-circuit on the first try. Dare I say that things are starting to look up?
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Location:
Richmond NSW
Registered:
September 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 08 May 2004 04:03
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well if u have to use cannons to get the most performance well so be it. cheers matt hope you sort out all ur probs:)
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sun, 09 May 2004 02:34
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The problems are sorted now, just gotta get the wiring done and fit up the exhaust.
Snagged a clutch master cylinder out of a Suzuki Baleno the other day, it's the smallest one I could find. This is being mounted and plumbed-in right now.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sun, 09 May 2004 12:56
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I promise everyone that when the engine is running again, I'll put up more pics of the setup.  Just have to find somewhere that will host 37mb of pics that I have so far... 
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Tue, 18 May 2004 16:23
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Wiring loom is 90% hooked up, bought exhaust lengths yesterday, all 316-grade stainless. Custom dump pipe has to be made up off the compressor flange, a 2½" 90° bend is being used for this. Nothing else will fit in that space. From there it's 3" everything baby... except for the 4" hot-dog and the canons.
Will it be this weekend??
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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 Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Fri, 21 May 2004 12:59
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Work has started on the exhaust system, with the custom dump pipe being made up off the compressor flange yesterday. Today the front section of the piping was made up, and it turns out that the 3" pipe is a bit of a squeeze through the crossmember, as it can't run below it because it's too low. I have to have 4 inches clearance between the pipe and the ground to keep it legal.
The exhaust is in several sections - the dump pipe, the section leading to the cat converter, the cat, the next section to the hotdog, the hotdog, a section to the Y-piece and the twin pipes off the Y-piece. Only the front section is done so far, and the rest is "planned" for the weekend.
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Location:
Brisbane, QLD
Registered:
February 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 22 May 2004 07:20
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so close
so so very close
you must be getting rather anxious to have this completed already
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 22 May 2004 07:26
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So anxious that words defeat the feeling...
JUST GIMME MY FRICKIN' CAR BACK ALREADY!!
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 29 May 2004 12:14
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Checked out the car again today, and the exhaust was in it's final stages. There's been a lot of work put into it so far, with one section of the exhaust pipe just after the rear diff (split off into a Y) about a foot in length, had about 10 different direction changes, all welded together seamlessly. It's this kind of detail that puts the car further behind in terms of getting it on the road again, but in front in terms of detail. I think it's two more welds to go and the exhaust system is complete. Just has to be hooked up to the underbody as well.
The car's wiring is complete, just gotta find a way to defeat the factory immobiliser so it can be hooked up to the ignition barrel and be turned over by key, not hot-wired like it currently is. I heard it crank over today, a sound I've been waiting for for quite some time now. It didn't kick because the fuel's not hooked in yet (the pump isn't wired in), but it did crank and it's definitely a lower sounding crank than a RAV4 ususally has. Need to wire-in the turbo timer and get the ignition right.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 31 May 2004 12:04
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Got the exhaust completed yesterday, pics are now up on my WebShots photo album here. Sorry Matt20v, you're not going to like the look of the ass-end, but ... you can't win them all.
Not much left to do now, just the rest of the wiring, refitting of stuff, all the (time-consuming ) fiddly shit.
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Club Member
Location:
Sydney, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 31 May 2004 13:05
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Holy shit man... There seems to be a shitload of welds in those rear pipes... Prolly explains the wait for so long...
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 31 May 2004 13:11
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Yep, it took a lot of lining-up to get them right, and a fair bit of progressive "path-correction" to mate up the left canon with the right.
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Club Member
Location:
Sydney, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 31 May 2004 13:23
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Nice to see it coming along finally ...
Hope to see it on the road soon...
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 10 June 2004 21:52
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New pics added to my gallery in webshots here.... The back end is seeing some improvements, although now the igniter coil and ECU could be about to make my day worse.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Fri, 18 June 2004 14:30
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I was patient before, but now this is pissing me off.  Both the coil and the ECU have been tested and cleared of any fault. The loom has been completely re-wired, and the only two other remaining components (the relay box and the distributor cap) have been tested and passed continuity and resistance.
So with all four of those areas covered for "spark", we're at a loss to find out what the problem is. It cranks over, so it's not the immobiliser, and fuel is getting delivered normally.
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Location:
Epping, Sydney
Registered:
April 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Fri, 18 June 2004 14:45
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eeek dude what a pain!
to be THIS CLOSE!!
what an amazing journey mate, hoefully it will be all sorted on Dyno Day.. you are not coming to the meetin on Monday are you?
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Registered:
August 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 19 June 2004 00:17
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Conversions are fun!
So whats the problem no spark at the plugs?
What does the immobiliser kill?
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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 19 June 2004 00:24
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have you checked that the dizzy is actaully giving a signal from its magnetic pickup? u probably have...
I want to see this at dyno day dude
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 19 June 2004 11:07
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RobST162 - depends on whether or not the RAV is back together.
BlackSupra - indeed they are fun, and a great experience - albeit sometimes frustrating. The factory immobiliser kills both fuel and spark.
Witzl - yeah everything has been checked, and you WILL see it at Dyno Day.
UPDATE!
It's ALIVE! 
Had a friend of mine bring an oscilloscope around to check out what was wrong with it. Turns out one of the "pulse wires" (??) was broken and then fixed up. It now lives and breathes. Unfortunately I didn't get to hear it running as it later ran out of fuel, so I brought around a 20L tin of fuel to give it a needy drink, so I can hear it tomorrow. Only thing is it might be a bit lean. A Jap-spec ECU and motor (expecting 100-octane but only getting 93-octane fuel), might conflict a bit - but octane booster can fix that up.
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I supported Toymods
Toymods Club Secretary
Location:
Sydney
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 19 June 2004 21:07
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w00t!!! That must've been the best fucking feeling in the world!
Congratulations dude - I can't wait to see this beast
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Location:
Sydney
Registered:
September 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sun, 20 June 2004 10:23
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finally the words i've been waiting to see in this thread, gotta be the best feeling now, congrats on having the patience to wait so long
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sun, 20 June 2004 14:57
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It's in re-assembly phase now, everything going back together. Also some clamps didn't quite have the best fit, which I'm changing over tomorrow. Other than that, it'll be sometime during the week when I can pick her up (hopefully).
Wish me luck.
Peace.
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Location:
Sydney
Registered:
January 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 21 June 2004 14:08
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Glad to hear it mate, this is going to be one awesome car! Cant wait to see it!
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 21 June 2004 14:18
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| Alchemist wrote on Tue, 22 June 2004 00:08 |
Glad to hear it mate, this is going to be one awesome car! Cant wait to see it!
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You got that damn right dude... I'm so unhappy that my camera doesn't have sound input (microphone) attached to it... I'd have recorded it when it kicked over today - such a glorious sound coming from such an unexpecting ride.
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Location:
Adelaide, SA
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Fri, 09 July 2004 22:16
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Anymore updates??
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 12 July 2004 00:55
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Apologies to all who expected to see it at Dyno Day 9... the turbo seals were shot, so I decided to have it rebuilt. The prognosis was bleak, as the CT20B (Jap-spec) is a very hard unit to find parts for. In a way I'm kinda glad that it was for two reasons - realistically, it saved me having to hi-flow the sucker down the track by spending an extra couple of hundred bucks on it when it was out of the car, and the second reason... everything else about this phase of the project has been done the hard way, I'm kind of glad this follwed suit!
Had to refinance one of my loans, but I got it done and it's back now, no longer a fully-fledged CT20B. Instead it's a hi-flowed CT26 beast with a 56mm steel compressor wheel (had to piss the stock ceramic one off), all sitting nicely in the polished CT20B casing. Looks shitloads better and won't blow out white smoke when it's warm now either! That was the only sign that the turbo seals were gone. Other than that, I couldn't fault it... it was the right turbo for the job, coming on boost at about 1800 RPM and zero lag. Now because of a slightly larger turbine, it will come on boost about 100-200 RPM later, but the result won't be that different that you'll notice it.
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Location:
Newcastle
Registered:
June 2004
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 15 July 2004 03:18
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Hey u got a link so nice external pics from the end of project i could only find the ones after mags went. or maybe post some pics
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 15 July 2004 05:30
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I've been saving up my 400+ pics of the entire install, from when it was a front-cut to what it looks like now. I'll be posting them up on my http://www.rav4oz.com/ site, but that's in the next month or so when I compile them all. I'll sift through my photos and see if I can get a few up here that are good examples of the work done to it. The rest of the progressional pics are on my webshots page, which has a link to it a couple of pages back... I think.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 17 July 2004 03:12
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The saga continues...
The beast got it's first run on Thursday afternoon , but the turbo couldn't boost more than 4Psi  . This led us to believe it's the fuel pump not delivering enough when needed, and subsequently 'starving' the engine of fuel. Got a Bosch 500hp pump from Injection Perfection on Thursday, and Chris was going to mount it up secondary to the stock pump this weekend.
As far as any other hurdles go, that's it. Race is over. I'm very pleased that it actually was road-bound once more, if only for a drive around the block. So upset I wasn't behind the wheel (or even in the car) when it was out. 
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 17 July 2004 03:13
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First page details updated!
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Location:
sydney
Registered:
May 2004
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 21 July 2004 07:39
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DUDE! UR CAR TEH R0XZ0R!!!
sorry to hear about the break in.
nice job!
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 21 July 2004 12:45
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Uh thanks dude - I think I'll take that as a compliment.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 24 July 2004 03:03
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It's all back together now, looking nice and tidy (if a little dirty on the exterior), the ECU has been relocated to it's permanent position (instead of on the passenger seat), the new Bosch 500hp has been fitted up and re-connected, we're still a bit dicey on the turbo even though it's been rebuilt and hi-flowed, it didn't sound quite right last time it went out for a round-the-block-blatt. This could have been attributed to a number of factors - ECU not handling lower-than-average fuel octane, turbo not quite balanced up right from when it was rebuilt, not enough fuel getting into the system making it starve at 4Psi, who knows. But we'll know soon as the RAV-GT4 gets it's run today sometime. Fingers-crossed.
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Location:
Sydney
Registered:
May 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 28 July 2004 08:14
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heya andrew
heard from chrises younger brother that your beast is running.....and running daym fine in its test run
apparently you should enjoy your beast
let me know when ya pick it what its like in your own workds
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I supported Toymods
Location:
sydney.au
Registered:
August 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 28 July 2004 09:24
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tell me your not still running 93 octane in it?
98ron at least for a JDM engine!
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Location:
Newcastle, NSW
Registered:
May 2004
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 29 July 2004 05:53
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ay andrew i just read your whole project from start to now and hell my eyes feel sandpaper, a shitload of respect goes out to you for making this happen and being so dedicated to the project, i love what you have done with the rav, until now i always frowned on ravs, but ya've changed my whole view on them, at the beginning of the year i baught an st162 celica that i was going to turn into a bit of a project, just after getting almost everything i needed to supercharge it, my engine blew on a dyno, so for the last 4 months i have been carless replacing the engine facing problem after problem after problem, my latest is some dipshit (namely me) took my altinator off without unhooking the battery and let the livewire drop onto my exhaust manifold, doing funny things to my electrics, if it wasnt for that she would be going again and on her way to becomming a project.
sorry for the long post and dont mean to hijack your thread, just wanted to say you have done a flippin awesome job so far...respect
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 29 July 2004 13:20
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ae86drift - no I'm not running 93 in it, I just gave her two 20L drums of Optimax, which is being used to fine tune the beasty now.
Neil - yep I talked to him tonight about how he went with that test run. He really shit his gear hard dude. He had his heart sucked to the back of his chest when he stabbed the throttle. He told me he had trouble breathing after he got out, as well as having the shakes in a BIG way. I'm guessing he was thinking the wheels would slip or something - ahhh, AWD. Traction City. That was his first drive of a turbo car as well. He's not sure whether he wants to go with Nissan or Toyota when he does his project, but he's now a huge fan of Toyota gear.
-=DV=- - I've converted a few people's thinking here in Toymods, them having the same contempt for the small AWD "vehicle that could". It's amazing how many fans you pick up along the way when you make a dream become a reality. For me it's just dogged determination and a huge will to succeed that's pulling me through this project. I'm just glad that I don't have a house, wife or kids to support - otherwise they'd be up shit creek! There's at least half a dozen other projects on RAV4's that I'm currently keeping up with at this point in time, all of them taking my lead in the modifications of their RAV4's. A couple are 3S-GE projects, the rest are 3S-GTE's mostly chopped out of MR-2's. Other's I've talked to are interested in turbo'ing the stock 3S-FE block in much the same way that AVO Turbo did, only with a revised setup and forged internals instead.
Also congrats goes to you for having the stamina to get through 23 pages (so far) of my project. I'm glad it was worth the read. I do hope your project comes along - it sounds like a nice project too. Yours has been off the road for as long as mine has now. I'm itching to get her back.
Peace guys.
[Updated on: Thu, 29 July 2004 13:23]
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 29 July 2004 13:42
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An update on recent happenings...
Because the new fuel pump was putting out a LOT more fuel than was expected (pumping it in at 55Psi, should be around 40), I had to get a fuel pressure regulator. I was going to go for a basic Malpassi reg, but I was more drawn to the 6061-billet aluminium of the Sard reg instead. Fittings also bolt up directly to the stock 3S-GTE fuel rail with fittings supplied. Today I got a fuel regulator gauge to mount onto the regulator. Should have gotten one of these to start with. This one goes up to 145Psi (or 1000kPa), and only cost $25 with a 1/8 NPT fitting. Hooked it up to the regulator tonight, will find out tomorrow how well we can tune the fuel coming in.
When the car started up tonight, the regulator seemed to alter the smoothness of the idle, if only momentarily. Was kind of refreshing to know that it's not going to sound like a modded Rotary with lumpy cams... It had a nice smooth note to it. After this is tuned in right, as far as we can see that's all that needs to be done.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sun, 01 August 2004 04:24
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We reset the timing back to normal (about 9° retard), then it developed this 'pop' at cold idle. The idle fluctuates too, although I don't know if this has anything to do with the 'pop'. Put on a timing light and 1st cylinder isn't firing (even with new plugs). The dissy cap was replaced yesterday, didn't fix it. Tested the igniter and CDI on Gary's ST205, wasn't the problem either. This leaves only leads and distributor to check out.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Tue, 03 August 2004 13:25
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The one thing we nearly overlooked (rotor button) turned out to be the key to the mis-firings in the engine. $10 well-spent.
We thought it was leads for sure, but the replacement distributor cap and rotor button made all the difference. Now it's purring like a kitten, with a very nice smooth note. Only one thing was disrupting the harmony of the engine, and that was a worn timing belt pulley (more like an oversized bearing if anything), which I listened to through a stethescope this afternoon. I got a replacement and Chris is fitting it up tomorrow. Once again, put everything back together and it's mine once more. Only need to plumb-up two pipes (one of which is the return of the BOV to the air intake, essential to avoid getting "canaried"), and the other is the factory catch-can equivalent. Anyway Chris will take it for another run tomorrow and make any adjustments (if needed) to further tune it.
So good to hear it running normally and SOOOO smooth.... not even a vibration when I put my hand on a panel. It's been nicely-balanced.
Bring it on!!
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Sat, 07 August 2004 07:26
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Would you believe Toyota sold me the wrong timing belt? Back when the engine was being reassembled I bought this and though nothing more of it. It turns out that the one I bought (Toyota supplied) hs 178 teeth in it, where the factory one needs to be 177...! Got another one (177-tooth) and that's being put on to replace it. Toyota were scratching their heads (as usual) as to why there were two different variants of timing belt with one tooth difference.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Registered:
June 2003
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Wed, 11 August 2004 15:49
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Nah nothing like that yet, although I would like to do that too.
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Registered:
June 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 12 August 2004 00:18
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Well if you want you can come out to Baulkham hills way and I can record you a movie and sound - but you gotta get here. I'm sure as hell not going all the way to miranda! Or even if you can get somewhere relatively close and we can meet up.
-J-
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 12 August 2004 07:04
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Well let me know if you're going to show up at one of the up-coming meets and you could get some audio/video of it then.
Updates...
Things are on-track for a release sometime this weekend. Bought some clamps and various hoses this afternoon to finish off the engine bay. Just need to fit them up and away we go.
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Location:
Sunshine Coast
Registered:
June 2004
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 12 August 2004 14:02
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Well....
My first thought was "A RAV4!? Why bother?".... Seems I was wrong.
Very well done.
Matt.
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Toymods member
I supported Toymods
Location:
Rydalmere, NSW
Registered:
May 2002
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Thu, 12 August 2004 22:02
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Thanks for your positive feedback Matt. There were a lot of skeptics and people putting down the RAV4 when Toymods was young, but I've since converted quite a few people's way of thinking. There still aren't that many people who think a RAV4 is worth modifying, but there are those who are determined (just like me) to make something of a "soft-roader", and turn it into a "ride". Most of these people (in Australia) can be found at http://www.rav4oz.com and the rest of the people around the world are at either http://www.rav4expedition.com or http://rav4world.com
I'll be looking forward to taking a test-drive in her this weekend. I don't think you'll be able to wipe the smile off my face.
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Location:
Melbourne
Registered:
December 2003
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Re: Andrew's 1999 RAV4/GT-Four Hybrid Project...
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Mon, 16 August 2004 23:49
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So Andrew, howd it go?U get to take it for its spin?Is it everything u wanted and more? Tell us how it all went, post some pics, sounds files or somethin. We're all hanging for it.
Congrats too mate, a true work of art
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