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Location:
Sydney
Registered:
October 2002
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 Help! 3SGTE - watercooled intercooler
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Sat, 01 March 2003 16:08
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For anyone who has one of these engines: does your intercooler feel hot or cold after its been running? Mine's been running hot (it feels as hot as the engine itself) ever since I've had it, & I read a story about a guy who had a 3SGTE ST205 who says it should be stone cold even after high speed running. He said he was getting an 'error 54' & his intercooler felt really hot, & he discovered his water pump wasn't running (i.e. the water wasn't circulating through the system), till he found a stuffed relay & replaced it. After he fixed it he said the extra power was amazing as the ECU wasn't restricting the boost.
I've been getting error 54 when I rev it higher than about 5000rpm, plus the engine smells if its been revving high (I think the under-bonnet insulation is burning!) as the intercooler radiates a disturbing amount of heat. All in all I'm thinking its not doing the engine very good.
I've got the Toyota 3SGTE maintenance manual to check all the circuits & diagnostics, but I'm gonna get someone else to check everything as my electronics knowledge is pretty basic. The relays seem fine (at least the ones I can find - my ST185 seems to locates some things slightly different to this other guys ST205), & I can't find the intercooler ECU to test where the problem might be (according to the manual its separate from the engine ECU, somewhere behind the dash). I've checked the water level which is fine.
I guess all I want to know is:
a) does your intercooler run cold?
b) has anyone had this problem? This engine code error is apparently very common.
Here's the link to the other guy's story: http://www.rennison.info/gt4faq/maintenance.htm#Ma intIcPump
Scroll down to 'Solving Code 54'.
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I supported Toymods
Banned User
Location:
Brisbane
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Sun, 02 March 2003 01:00
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Error 54 could be anything to do with the intercooler! Check the water level for starters, then check the connection to the water level sensor, then check the connection to the water pump!
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Location:
Sydney
Registered:
October 2002
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Re: Help! 3SGTE - watercooled intercooler
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Sun, 02 March 2003 21:42
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Water level has been checked, water level sensor is working fine (checked by disconnecting sensor, engine light comes on, reconnect, engine light goes out). The water pump should run when the throttle is open, but it doesn't. I connected the battery direct to the pump, & it turns over, so there must be an electrical problem somewhere.
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Location:
Cabramatta, NSW
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Sun, 02 March 2003 23:47
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I've had my water pump fail too.
The intercooler shouldn't be cold, but you should be able to comfortably put your hand on it after a drive. Well, that's with my setup (different engine, different car, no bonnet vent).
Maybe you should hook up a test light to the pump to see if it ever turns on?
Has it every worked?
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Location:
Brisbane
Registered:
February 2003
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Registered:
September 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 08:23
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Yeah mine is pretty cool after driving... i have mine hooked up to a switch and i run it pretty much full time.... its better that way
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I supported Toymods
Banned User
Location:
Brisbane
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 08:30
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Where abouts do you live dude?
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Registered:
September 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 08:34
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Who me or Tony?
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I supported Toymods
Banned User
Location:
Brisbane
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 08:38
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Tony
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Location:
Montrose, VIC
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 12:01
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Hook the pump up to the battery and go for a drive, see what happens
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Location:
Sydney
Registered:
October 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 12:57
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Okay...
1. No, the pump has never worked (I bought the car 4 months ago). I just never realised it didn't work. It's always run hot, & I wasn't sure if this was normal or not till I read it was supposed to be reasonably cool. Then the check light starting coming on frequently.
2. I live in Sydney. Why do you ask?
3. I've connected the battery to the pump, & it turns over, so all I need to find is where the bad connection is somewhere between the pump & the ECU. All the fuses I can find related to it seem fine. How do you check if a relay is working? If I could find the intercooler ECU it might tell me where the problem is.
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I supported Toymods
Banned User
Location:
Brisbane
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 13:21
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There is no intercooler ECU it is controlled by the main ECU.
Look here for some wireing diagrams: http://gtfour.supras.org.nz/diagrams.htm
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Location:
Cabramatta, NSW
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 22:37
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You can test a relay by swapping in another one and seeing if that works... hehe
Why not just run it full time? Shortens the life of the pump, but at least you have no worries...
I fucked around for ages setting up the pump to turn on when boost hit a certain level, then I was sick of not know if it pumped or not so I just run it full time now... 
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Location:
Sydney
Registered:
October 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 22:43
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I thought about running it full time, but then I found out how much a new pump costs from Toyota if I had to replace it.... $1400!!!
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Location:
The Central Coast
Registered:
October 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 22:54
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After reading a couple of links supplied by spectral, I'm partial to having the pump running all the time.
What probably needs to be done to make it completely successful, is have a temperature control switch run in between the normal circuitry.
So, toyota made the waterpump turn off while the car was at idle, to extend the waterpump life.
I say that's all well and good, but only if the intercooler temperature stays below a certain temperature. As soon as it heat soaks too much while sitting at the lights, it should fire up again.
My two cents anyway. Probably needs a little tricky custom wire up job for that.
As for Tony's problem, good luck mate, your choice if you want to wire it up permanently for cool runnings. Be prepared to fork out for a new waterpump in a year or two, just in case the constant running burns it out.
Maybe it's time for a sparky to have a squiz. 
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Location:
Sydney
Registered:
October 2002
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Re: Help! 3SGTE - watercooled intercooler
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Mon, 03 March 2003 22:57
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ST185R has a separate ECU for the intercooler (there's a diagram of it in my engine manual) which is then connected to the engine ECU. The book says its located behind the instrument panel on the passenger side, but I couldn't find it (unlike the engine ECU which is underneath the radio which is easy to find).
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I supported Toymods
Location:
melbourne
Registered:
June 2002
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Re: Help! 3SGTE - watercooled intercooler
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Tue, 04 March 2003 00:15
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here is an idea, put a switch in your car (one of those covered flick cover aircraft switched would be cool) and hook up a new realy to drive the pump, then you can leave it turned off most of the time (like it eems to be now) and then turn it on when you want to cain it.
alternately, leave it switched on and turn it of when you are sick of caining it.
a new (which will work for sure) relay will cost you all of ten bucks, wiring would be no more complex than wiring a set of driving lights.
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Location:
Cabramatta, NSW
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Tue, 04 March 2003 00:54
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$1400?!
$200 for a brand new Davies Craig EBP. It's been working non-stop in my car for over a year now.
http://www.daviescraig.com.au/newproduct_ebp.html
Great flow, light, and compact. And I got good service from them when I was making enquiries.
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I supported Toymods
Banned User
Location:
Brisbane
Registered:
May 2002
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Re: Help! 3SGTE - watercooled intercooler
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Tue, 04 March 2003 07:07
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I'm telling you that in the ST205 there is no ECU for the intercooler pump.
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Location:
The Central Coast
Registered:
October 2002
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Re: Help! 3SGTE - watercooled intercooler
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Tue, 04 March 2003 22:28
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I don't think he's arguing that in the ST205 there is a separate ECU.
He has a ST185, which DOES have a separate ECU for the intercooler.
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Registered:
June 2002
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Re: Help! 3SGTE - watercooled intercooler
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Tue, 04 March 2003 23:22
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You could easily wire in a aftermarket adjustable thermostat like the ones on thermo fans, and then use a relay to switch the pump in and out. This way you could adjust what temperature the pump goes on and off.
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Location:
The Central Coast
Registered:
October 2002
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Re: Help! 3SGTE - watercooled intercooler
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Tue, 04 March 2003 23:47
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Yes that could work.
You'd want the sensor to make the water pump turn on independantly once the temperature got above a certain level.
You'd never want it to switch off though...ie get's cold, sensor says "That's enough" then no more cooling.
Useful for a system that was already functioning properly though, say sitting at lights and gets too hot, overriding the ECU to switch the pump back on at idle.
Sure that could be a cheap fix, and probably a little better than running the pump all the time.
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Location:
Perth
Registered:
February 2003
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Re: Help! 3SGTE - watercooled intercooler
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Wed, 05 March 2003 02:49
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The Toyota engine manual should run through all the diagnostics for this, the ST205 one does anyway.If not go have a talk to the guys on the GT4 mailing list, its a very common problem so the will be able to help you for sure.
http://autos.groups.yahoo.com/group/gt4/
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Location:
Melbourne
Registered:
September 2002
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Re: Help! 3SGTE - watercooled intercooler
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Wed, 05 March 2003 06:05
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Hey Guys,
Well I think the best/easiest thing to do is wire a switch to the relay that is on the passenger side of the strut brace (the water pump relay). Simply you just over ride the relay.
I ran a wire connected to two of the terminals on the relay into the cabin through the gromet that the wiring loom goes through and put a switch in the middle of the wire.
If your not good with electronics then take it to a auto electrician and tell them that you want an over ride switch for that relay, so u can run the pump constantly, shouldnt cost more than $20-30 for the wire/labour but not sure about the switch.
Alternatively get out your wire, soldering iron, shrink wrap, wire cutters + multimeter and go the hack ;p
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