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I Supported Toymods
Location:
perth
Registered:
September 2002
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4AGZE SC pulley mod (ea falcon air-con pulley) info
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Sun, 24 July 2005 11:56
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Hey all,
Just completed this for my car and thought id leave a little documentation for those who are thinking about an upgrade soon.
Summary of costs and what is needed
- EA falcon air-con pulley : $20 (wreckers)
- SLEEVE : custom metal sleeve to bring internal bearing diameter of EA pulley down to same as standard SC pulley (30mm). This slips into the bearing of the EA pulley so it can attach to the SC properly. From memory the metal sleeve has to be 35mm outer diamter, 30mm inner diamter, 19mm deep. Having it 19mm deep instead of 20mm allows the threaded piece of metal that holds the Pulley itself to the SC to grip the bearing instead of the sleeve when you are attaching the new pulley. This will prevent the sleeve from sliding on the bearing.
OR
- BEARING : custom bearing with 50mm outer diamter, 30mm inner and 20mm depth. We could not find anything like this so had to go the sleeve approach. Any information on this would be greatly appreciated
- arc welder to weld the standard SC clutch to the face of the new pulley. This is the easiest approach as the SC clutch face and new pulley face are difficult to work with.
Notes
- 14psi is awesome, feels like its running too rich now
- ITS LOUD AS HELL. The SC whine is very loud even at idle.
- belt requirements : 3PK895 The new pulley also sits slightly more toward the engine with the above setup so i had to buy a thinner belt that could operate in the overlap between the pulley alignment. This problem hopefully can be avoided by spacing the new pulley out by about 5mm...not ripping it out again just yet!
Hope that helps 
-daniel-
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Location:
Canberra
Registered:
April 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 00:41
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I'm looking at doing this mod this week.
Have you retained the elec clutch or is the pulley now solid mounted??
Cheers
Steve
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Location:
Adelaide
Registered:
January 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 02:06
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I'm guessing since he's welded the clutch face from the original pulley onto the EA pulley that the clutch is still being used.
I mean, whats the point of welding it on there if it's not being used...
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I Supported Toymods
Location:
perth
Registered:
September 2002
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 Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 02:58
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haha yeh i welded the existing SC clutch to the new pulley face because
1. i needed it to drive the SC itself via the splines that are inside the the shaft that the pulley free wheels around. The ea falcon clutch unit may not fit these splines...however ive heard it does
2. the ea elec clutch looks weak
3. i FRIED my electro magnet on my SC which is the reason for the change.
IMPORTANT
-make sure you get an ea pulley with good bearings. Even spend the $44 for a brand new bearing from "Statewide bearings" or somewhere like that. My car whines so goddamn loud even at idle now and i think its mainly the old pulley bearing..it goes like a shower of shit though!
GETTING THE SC PULLEY OFF
1. remove the electromagnetic clutch (just unbolt)
2. remove a circlip
3. remove a threaded weird bolty thing with four grooves in it that actually screws down on the bearing of the pulley. i used hammer and screwdriver
4. after that i think u can just slide the pulley off.
-daniel-
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Location:
Canberra
Registered:
April 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 03:20
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Excellant! I'll go have a play with it now.
I'm also running a HKS crank pulley as well, so i got no idea what boost to expect. 
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 03:29
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Wicked man!
well i hit a solid 15psi with std crank, and the thinner bosch 3PK895 belt i have to use seems to be holding so far.
Make sure you space the ea pulley out the correct amount ~5mm if you can.
Just remember the SC12's have been proven to melt at 18psi
Peace
-daniel-
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Location:
Canberra
Registered:
April 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 04:27
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lol, chargers are cheap 
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Location:
Sydney
Registered:
November 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 13:07
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how do u space it out 5mm
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Location:
Canberra
Registered:
April 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 13:19
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I'm guessing a washer would be dodgy, but sufficient
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Location:
Canberra
Registered:
April 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 13:26
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I should be running around 15-18PSI with my larger crank pulley, in theory. SHould be good 
You got any times or dyno figures yet, bayka?
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 25 July 2005 14:21
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yeh was thinking washer or something.
Dynoed at genie with stock pulley and got max of 132hp / wheels at 5500rpm goddamn timing keeps getting hammered....think its the knock sensor im still trying to solve the problem.
18psi may be ok, just went for a drive in a 'wagonboy's ...my god...he said he was getting 20psi for a while on std sc12!
Peace
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Location:
Sydney
Registered:
November 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 26 July 2005 06:02
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so how long did the conversion take.
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 26 July 2005 07:08
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Car was off the road for a week, mainly because
-we stuffed the first ea pulley bearing
-had to wait a few days to use a friends workshop
-ripped up first 5pk type belts 
Time Breakdown
1. remove SC12 and std pulley (first time) : 3hrs
2. machine 30mmx35mmx19mm metal sleeve : 2hrs
3. reassemble sc12 and weld clutch to pulley : 30mins
4. completely cut-and-shut ABV : 2hrs
5. put sc12 back in and start : 2hrs
-daniel-
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Location:
Canberra
Registered:
April 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 26 July 2005 07:28
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| bayka wrote on Tue, 26 July 2005 17:08 |
4. completely cut-and-shut ABV : 2hrs
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What did you do here? will just "jumping" the ABV lines be enough?
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 26 July 2005 18:00
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I honestly don't know dude. We just wanted to be sure so we did the following.
1. removed the wastegate looking thingy on inlet side (which would be in a vacuum) and simply cut a thin piece of sheet metal to size and bolted that on instead. This gives HEAPS more room to access SC and throttle body assembly.
2. found a solid cylinder of metal that fitted the ABV pipe on the exit high pressure side, drilled holes though the cylinder and the abv outlet steel pipe lip. Then simply slid in the cylinder and put a long bolt though both holes. That way we can be sure it wont burst out while boosting. Also ran a bit of silicon around the cylinder before we put it in to avoid hissing.
So far the only problem ive noticed is i seem to be getting a fuel cut or something in higher gears at 15psi. Its weired, definately happend since ive run 15. Its sort of like the power drop you get when your bouncing the revs but happens at like random rpm in 3rd and 4th. Only noticed for first time 2nite in the cold...perhaps its when the MAP detects a solid 15psi??
what do you guys think?
Peace
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Location:
Toronto, Downtown
Registered:
September 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 26 July 2005 21:54
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i think you should get an aftermarket ecu
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Location:
Canberra
Registered:
May 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 26 July 2005 22:14
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So, you're running a fixed pulley and no ABV?
I'm very curious to see how long the 'charger lasts.
Can you do me a favour and let it idle for a few minutes and tell me if the SC gets hot?
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Location:
Toronto, Downtown
Registered:
September 2004
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 26 July 2005 23:10
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yep thats correct.
Aftermarket ECU is out of the question at the mo
I'll touch the SC12 after a few mins of idle once engine is warmed up and see how hot it is..my thoughts are it'l be ok. Its a toyota! she'll be right mate 
I know one thing though, because ABV is completely removed and im not running SC clutch at idle it certainly is LOUD, i still don't know if its the pulley bearing or just the whine of the SC being loaded up against a closed engine intake or something.
Hey my friend and I were thinking about how running 15psi makes the std 4agze run really rich....why not counter that for the moment by advancing the fuck out of the timing? 
Someone tell me 'no' before i get silly!
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Location:
Toronto, Downtown
Registered:
September 2004
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 26 July 2005 23:44
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YES
Definately interested in the fuel controller. Im assuming its sort of like an s-afc? Does it work by tricking the MAP sensor?
How hard is it to wire up and how much do you want for it?
Can you give me exact brand / model and some more details?
p.s. what boost are you running on your 4agte?
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Location:
A.C.T
Registered:
May 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 02:04
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Hey champ can you get some pics up of the build thanks.
Mark
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 02:09
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sorry man, no pics this time. Car was off the road for so long the number 1 priority was to get it going again.
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Location:
Newcastle
Registered:
August 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 02:25
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Hmm, wonder how long the charger will last.
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Location:
Newcastle
Registered:
August 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 02:28
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What is the size of the pulley just out of Q.
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Location:
Toronto, Downtown
Registered:
September 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 04:18
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| bayka wrote on Wed, 27 July 2005 09:44 |
YES
Definately interested in the fuel controller. Im assuming its sort of like an s-afc? Does it work by tricking the MAP sensor?
How hard is it to wire up and how much do you want for it?
Can you give me exact brand / model and some more details?
p.s. what boost are you running on your 4agte?
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its an r-spec fuel controller i bought it off a guy on these forums that i know quite well who was running it on his 4age sprinter...
I dont know how exactly it works but id imagine it tricks something i can find out how to wire it up for you it dosent look overy complicated it dosent have many wires.
It has 3 dials which you can adjust the fuel to either lean or rich across 6 different rpm bands i belive. its only small about the size of a packet of smokes would be nice to mount under the dash..
Ill post some pics tonight if you want i remember looking up the japanese website where you could get the instruction manual in english.
I paid $100 for it and thats all id want for it including postage to where you are...
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 13:36
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wiked, sounds good. PM'd
Just to let whoever asked know. I felt the inlet and outlet pipe temps from SC / top mount intercooler today after a spirited drive...my god the inlet pipe is like 60 celcius, the outlet was WAY to hot to touch.
Looks like front mount is a must @ 15psi. There may be huge power gains to be made by cooling that inlet air.
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Location:
Canberra
Registered:
April 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 13:42
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I'll be running a FMIC as well as a haltech and water injection, should all be in within 3 weeks I'll let you know how it goes
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 13:46
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hell yeh!
Drive over to Perth when its done so i can have a look 
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Location:
Toronto, Downtown
Registered:
September 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 13:53
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| bayka wrote on Wed, 27 July 2005 23:36 |
wiked, sounds good. PM'd
Just to let whoever asked know. I felt the inlet and outlet pipe temps from SC / top mount intercooler today after a spirited drive...my god the inlet pipe is like 60 celcius, the outlet was WAY to hot to touch.
Looks like front mount is a must @ 15psi. There may be huge power gains to be made by cooling that inlet air.
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yeah for sure man
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Location:
Perth
Registered:
January 2005
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 14:11
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Hi Bayka,
I still haven't got around to installing that E58-LSD gearbox I bought off of you.
Just with all this talk of crazy boost, thought I'd mention that I've got 18 PSI on my MR2's boost gauge at the moment, but that is on an 8.0:1 engine with an SC14 which I'm spinning no faster than you're spinning your SC12 to get 14psi.
Of course I've got a rather large number of modifications, including my own home built custom ECU, but the engine is still standard internally. At this level 365cc's aren't enough above 6000rpm to maintain the rich AFR (0.8 lambda or so) needed, so I whacked on some 440s.
I expect that if I drove the car hard for more than a few moments I'd kill the supercharger very quickly (melt the rotor coating), but I'm planning on getting the rotors re-coated with a higher temp coating (place in Perth can do it). And doing some testing with thermocouple and installing a home built water injection system at the supercharger inlet (uses aquamist nozzles). I think the SC will survive with this setup.
I have noticed that currently the SC gets BLOODY HOT after a few mins of even medium boosting.
Regards, Nick.
http://www.e-wire.net.au/~nrparker/MR2/NewEngine/n ew_engine.htm
Go to bottom of page for Video at moderate boost during tuning on road..
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 27 July 2005 18:35
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hi Nick.
haha is that so?
Any chance you want to part with the 11c drive shafts temporarily?
haha but seriously, im looking for some spare shafts so i can pull mine out and get all four CV joints rebuilt this week.
440cc injectors..COOL how much did they cost you?
How do the sc14's rate up to their smaller brother in thrashability?
Cheers
-daniel-
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Location:
Newcastle
Registered:
May 2004
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Location:
Newcastle
Registered:
May 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Thu, 28 July 2005 04:44
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| bayka wrote on Thu, 28 July 2005 14:38 |
Im don't think so, one of the wreckers asked me that aswell.
If i had to give an answer id say NO its not the idler, its on the air-con compressor.
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true, sorry i editied my post after finding this out for sure, but for anyone else, there is both a idler pulley and air-con pulley, dont be confused, a couple of the wreckers i called asked me if it was the idler, i had no idea  but now i know it is not, u want the one that comes from the air con, nothing else.
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Location:
Newcastle
Registered:
May 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Thu, 28 July 2005 04:46
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also does the aircon pulley have "ribs" in the pulley or is it a flat surface? u know where the belt goes, should it have grooves there?
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Thu, 28 July 2005 04:47
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yes it has ribs that fit all 3pk / 5pk belts
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Location:
Newcastle
Registered:
May 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Thu, 28 July 2005 04:51
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for fucks sake then wtf did the fag at the falcon centre give me, mine is a flat surface, i went in asked for an ea falcon air con pulley. he comes out, i say "that's defintly the air con pulley?" as i was expecting ribs also, he goes " yep, just pulled it off the car then, fuckin ford drivers, WTF!
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Location:
Newcastle
Registered:
May 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Thu, 28 July 2005 04:56
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thanks mate would be appreciated, as i gotta go past the joint on the way to uni in an hour anyways, so it would help to know what it looks like this time.
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Location:
Newcastle
Registered:
May 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Fri, 29 July 2005 00:05
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thanks mate, i did actully go past the place in the afternoon, took the old pulley they gave me back and said its not the one i want, they said well the engines out the back, come and tell us, so out i went, saw the real a/c pulley.. "that one". So all good now i have myself the proper pulley with good bearings too i made sure. So now i just need to get a sleeve machined 35mmx30mmx19mm. Will try and get that done tomorrow.
Thanks for your help man, much appreciated.
More questions to come no doubt when i delve deeper into the conversion, lol.
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Location:
Melbourne
Registered:
November 2004
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Location:
Taree, 4h nth of syd
Registered:
May 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Sun, 31 July 2005 12:33
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Hey there mate,
what do you think would happen if u left the ABV on???
thanks
Eddie
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Location:
melbourne
Registered:
January 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Sun, 31 July 2005 13:36
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If he left the ABV on it would limit the boost to 8psi... and the rest would be vented
Hey can you take pics of the disassembled SC pulley, clutch etc...
I have a GZE but if you have yours off sometimes I would love pics of the clutch mechanism.
Good work btw I might try something like this
Thanks
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 01 August 2005 06:39
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No probs.
Just for the record i'll explain what we learnt from it.
-the SC12 pulley free wheels (on a bearing) around a solid tubular shaft which is 30mm in diameter.
-inside the tubular shaft there is a spline that physically drives the SC, this is what the clutch slides onto.
-the clutch face freely slides on the face of the SC pulley. There are 3 permanent magnets mounted on the clutch face slightly sunken so when the two faces grip the magnets are not worn off.
-an electromagnet sits behind / inside the SC pulley and this is what the 12V feed to the SC goes to. When you feed 12-14V to the electromagnet it magnetises the SC pulley causing the permanent magnets on the clutch face to attract to the pulley face and grip.
So when you hear silly ppl like me blowing the SC clutch, in fact i think they are blowing the electromagnet.
Cheers
-daniel-
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 08 August 2005 17:07
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Hi all,
Just wondering if anyone else has followed the black path to 15psi?
If so whats the noise level like?
Does it whine like a hoe at idle even with good bearings?
Peace
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Location:
Sydney
Registered:
November 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 10 August 2005 13:48
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hey guys, so u reckon ill kill the motor with a stock inter-cooler. and will a afm stock ecu handle 15psi i heard it will only take 14psi max! thanks
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I Supported Toymods
Location:
perth
Registered:
September 2002
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Location:
Toronto, Downtown
Registered:
September 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Fri, 12 August 2005 04:11
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stock cooler is ok but for 150 buks you can buy a 1ggte i/c and make some piping up to front mount it and should keep inlet temps lower
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Location:
Sydney
Registered:
November 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Fri, 12 August 2005 13:32
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ok sweet i will be trying the ea conversion very soon
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Registered:
August 2004
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 29 August 2005 13:26
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| bayka wrote on Mon, 25 July 2005 22:21 |
yeh was thinking washer or something.
Dynoed at genie with stock pulley and got max of 132hp / wheels at 5500rpm goddamn timing keeps getting hammered....think its the knock sensor im still trying to solve the problem.
18psi may be ok, just went for a drive in a 'wagonboy's ...my god...he said he was getting 20psi for a while on std sc12!
Peace
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Get it dynoed somewhere that has an accurate dyno as genie has always read high, cause if you wanna go buy that mine did 138 stock exhaust and everything.
When i fitted the NEVO i was sometime peaking at 1.22bar , but since i fitted a FMIC i have been getting .95 at the most on a cold nite, but because there is such a hughe difference in inlet temperature now it actually goes harder. You felt the cooler piping on mine after we took car for a hammer , so just imagine the temp of the air going straight thru your interwarmer and into the engine hahah.
Im getting another SAFC-II for the turbo conversion on the GT Apex dan so i can probably get a price for you too. I can wire this in for you in about 15mins, piece of piss.
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Location:
Newcastle
Registered:
July 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 08 November 2005 11:13
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just an aside to this....
im looking at doing this atm.
1) when you said "SC clutch face and new pulley face are difficult to work with"
when you said difficult to work with what was the issue ? as i dont want to weld the clutch as i want to keep the charger clutched.
and secondly to anyone else. ive spoken to my mate who works for a machine shop and he is going to whip up the sleeve foe me, but also it will have a spacer as a component so that it brings the pulley in place so that the belts line up and you can use a 5pk belt.
this obvouly comes with the provisor or minimum quantity.. any one interested in one ? the cost should be relativly low but id just like the guage interest.
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Location:
was adelaide now newcastle
Registered:
February 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Sat, 19 November 2005 21:56
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im interesed in a sleave, arround what price do you think they will go for?
matty.
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Location:
Newcastle
Registered:
July 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Sat, 19 November 2005 23:04
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im currently playing around i think i may have a found a bearing that eliminates the need for the sleeve however a spacer will still be required to line the belts up and to mount the electromagnt properly.
cost wise will be bugger all. speaking to my mate about approxiamte costs to get him to make them up they will cost very little the only issue would be a minimum quantity which i felt was fair. so id be simply passing them on at cost. i dont have the exact numbers atm but expect it to be consuamable cost.
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Location:
sydney
Registered:
June 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Mon, 21 November 2005 09:05
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Hey,
Put me down for one of whatever you come up with, sleeve and spacer, bearing and spacer, whatever. I am wanting to do this as soon as i finish my uni exams and get some time to spend working on the car.
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Location:
Brisbane
Registered:
February 2003
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 22 November 2005 05:30
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I will grap one too if you are making a bunch up.
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Location:
Melbourne
Registered:
May 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Tue, 22 November 2005 15:03
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I want one. PM some bank details and I'll sort you out.
dan
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Location:
northern beaches
Registered:
August 2002
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Re: 4AGZE SC pulley mod (ea falcon air-con pulley) info
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Wed, 23 November 2005 06:11
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a mate off mine has just brought a gze and wants more power, so im 98% sure he would be down too.
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