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6G Celicas Forums _ Forced Induction _ 7A-FTE made in Germany

Posted by: Hafkai Dec 27, 2008 - 5:10 AM

Hi, after over a year of gathering parts my Celica finally is in the garage and gets her custom header, exhaust and some other stuff.
Yesterday we fitted the big Evo9 intercooler, i had to get the ST205 crash bar because the stock one is to tight, intercooler piping was done too and i'm very happy with it. I will use the stock ST205 air filter box, since there is not much space between the filter box and the engine, the IC piping is a little bit tricky but it looks like we found a good route.









The header will be done in the next days.



Short list of parts i'm using:
- Garrett T25 Turbo from a CA18DET
- Mitsubishi EVO 9 Intercooler
- E-manage Ultimate
- Innovate LC-1 Wideband
- ST202 3S-GE Injectors (372ccm)
- ST205 Fuel Pump
- Bosch Blow-Off from a Audi S3
- Custom Header and 3" Exhaust
- dozens of other small parts wink.gif

Posted by: Pollux Dec 27, 2008 - 7:24 AM

Nicht schlecht, Herr Specht
(Not bad Mr. Woodpecker woot.gif )

Has it been on the dyno yet?
What's the power output?
Why didn't you just do a 3s-ge or 3s-gte swap?

Du bist der mit den Ultraleggeras, der öfter mal auf dem Eurospeedway unterwegs ist, stimmts?
(Not relevant to US-habitants... i apologize for writing german)

Posted by: hurley97 Dec 27, 2008 - 4:58 PM

Holy hell!!! Is that massive intercooler really necessary on a 7A?? How much boost are you planning to run?

Posted by: malpaso Dec 27, 2008 - 4:59 PM

amazing job...

Posted by: RickJamesBish Dec 27, 2008 - 5:01 PM

Sieht gut aus. Wie viel kW sind in planung?

Posted by: Hafkai Dec 27, 2008 - 5:51 PM

QUOTE (Pollux @ Dec 27, 2008 - 1:24 PM) *
Why didn't you just do a 3s-ge or 3s-gte swap?

Du bist der mit den Ultraleggeras, der öfter mal auf dem Eurospeedway unterwegs ist, stimmts?
(Not relevant to US-habitants... i apologize for writing german)


Joa der bin ich smile.gif
I'm not a big fan of the 3S-GE(except BEAMS biggrin.gif) and i dont want to swap the whole engine. The 3S-GTE is without a doubt the better base for power but i'm not looking for that much and 7A-FTEs are very rare in germany..

QUOTE (hurley97 @ Dec 27, 2008 - 10:58 PM) *
Holy hell!!! Is that massive intercooler really necessary on a 7A?? How much boost are you planning to run?


Absolutely not biggrin.gif, for some fun on the streets a much smaller intercooler would be enough, but i will use the car for trackdays and ~15min full throttle ask for something that is able to take the heat and release it fast enough, i think the Evo intercooler is a good choice for this job.
I don't plan to run much boost, 8 or max. 10psi on the track, the 7A may take more in daily driving with only short boost attacks.. but a racetrack is something different.

Posted by: hurley97 Dec 28, 2008 - 12:06 PM

I have a small water to air that sits in the bay and it is awesome. But I also daily drive the car, I don't race it on the track. Although I'd have to say it would probably do better in longer and harder running conditions like highway or track use rather than around town or at slower speeds, reason being the increased amount/cooler air getting to the heat exchanger mounted in front. Water has a better cooling ability than air which is subject to the outside temperature. The w2a itself under the hood is ice cold after a highway run in the summer.

Posted by: lagos Dec 28, 2008 - 5:12 PM

most efficient mounting of an intercooler to date. nice job.

Posted by: njccmd2002 Dec 28, 2008 - 7:05 PM

that would block the air to the radiator, yes?

Posted by: enderswift Dec 28, 2008 - 8:45 PM

x2, wont the trackday benefits of the intercooler be offset by the fact that now your engine will be running alot warmer? i imagine the cooler air charge wont matter thing when the cylinders are surrounded by a piping hot water jacket 0.o

Posted by: Batman722 Dec 29, 2008 - 12:16 AM

QUOTE (njccmd2002 @ Dec 28, 2008 - 7:05 PM) *
that would block the air to the radiator, yes?

not as much as your AC condenser does.

QUOTE (enderswift @ Dec 28, 2008 - 8:45 PM) *
x2, wont the trackday benefits of the intercooler be offset by the fact that now your engine will be running alot warmer? i imagine the cooler air charge wont matter thing when the cylinders are surrounded by a piping hot water jacket 0.o

um, no.
First, your AC condesor blocks air flow to the radiator more than anything. It's bolted directly in front of your radiator and are your cylinders surrounded by a piping hot water jacket ? nope.
Second, both the condensor and that IC have fins (just like a radiator) and air passes through them, hence cooling the coolant or air you have running through it. With his IC there is plenty of room for air to get through and around it to cool everything just fine.

Posted by: CelicaST_CALI Dec 29, 2008 - 12:22 AM

Plus he has fans...



great 7afte build so far!!!Isnt 3" exhaust a lil big for a 7afte?

Posted by: enderswift Dec 29, 2008 - 12:53 AM

haha you're right, completely forgot about the condenser rolleyes.gif
dont the cooling passages run between the cylinders? maybe waterjacket isnt the right term... ill check out what my haynes manual has to say


either way back on topic, nice setup thumbsup.gif

Posted by: Hafkai Jan 4, 2009 - 9:05 AM

Header is completed and the rest of the exhaust will be done this week.










Posted by: enderswift Jan 4, 2009 - 2:26 PM

thats some CLEAN exhaust work there

Posted by: CelicaST_CALI Jan 4, 2009 - 3:05 PM

awwwww a cat frown.gif wheres the fun in that?

Posted by: SpoonR530 Jan 4, 2009 - 9:02 PM

Gotta love that German Engineering biggrin.gif biggrin.gif biggrin.gif

Posted by: Batman722 Jan 5, 2009 - 12:18 AM

QUOTE (Hafkai @ Jan 4, 2009 - 9:05 AM) *

do you plan on not using the fans anymore ? it looks like it's going to be a tight fit....
I would of suggested putting them or at least one on the opposite side of the radiator but with that IC and the big horn there, might not be much room there either.

also, get a new radiator. Yours looks about 14 years old and with the excessive heat from that set-up you'll kill that one sooer than you think.

Posted by: Hafkai Jan 5, 2009 - 5:19 AM

I'll try to fit the stock fan on the other side of the radiator, if that doesn't work i'll get one or two Spal fans. They're much thinner, should fit without any problems.
The hot side of the turbo will get a heat shield, the header maybe too but i'm not shure about that.

Posted by: malpaso Jan 5, 2009 - 5:41 AM

QUOTE (Hafkai @ Jan 5, 2009 - 11:19 AM) *
I'll try to fit the stock fan on the other side of the radiator, if that doesn't work i'll get one or two Spal fans. They're much thinner, should fit without any problems.
The hot side of the turbo will get a heat shield, the header maybe too but i'm not shure about that.


It will work for sure wink.gif


Posted by: Hafkai Jan 16, 2009 - 1:48 PM

Got new pics, there are still some things to do but the engine should run this weekend.










Posted by: Sebby Jan 16, 2009 - 2:40 PM

Grat job mate,keep up the good work!!

Posted by: playr158 Jan 16, 2009 - 2:49 PM

Nice work, looks like your project is coming along very clean.

Posted by: Hafkai Jan 17, 2009 - 5:02 PM

More pics smile.gif










Posted by: normality78 Jan 18, 2009 - 2:34 AM

i like the way how you fabricate the downpipe housing. Looks great...

Posted by: Hafkai Jan 19, 2009 - 6:40 PM

IT'S ALIVE!! biggrin.gif

Today we finaly got everything done what's needed to let the engine run. After 10 minutes wondering why my E-manage and the starter don't work, my friend simply asked me "immobilizer??"... unbelievable how fast you can forget something like that laugh.gif
The engine runs a bit rich at idle and closed loop didn't worked, maybe a problem with the stock lambda probe. Tomorrow we put the car on the dyno and i try to set up the E-manage so that the car will run not too bad with boost, fine tuning will follow the next weeks.

http://www.youtube.com/watch?v=Mz2k1th25F4

and some pics





Posted by: Hafkai Jan 20, 2009 - 5:11 PM

http://www.youtube.com/watch?v=C8E745EkCVw&feature=channel_page smile.gif
First run with some engine knock because of too advanced ignition timing making the engine stutter above 5000rpm, i retarded the timing about 2-3° in the next runs.


Posted by: normality78 Jan 20, 2009 - 9:15 PM

nice figure...!! cant wait to see full dyno plot.

Posted by: normality78 Jan 20, 2009 - 9:24 PM

im watching the video but i also notice some knocking sound behind. Is that the engine knock sound you're refering to? Coz i can hear it even on low rpm and gradually increasing as ur rev up

Posted by: Hafkai Jan 21, 2009 - 4:54 AM

The loud knocking sounds are from the dyno. The actual engine knocking isn't audible but you can hear that the engine doesn't rev freely in high rpm. Too bad i don't have a video from the other runs.

Posted by: normality78 Jan 21, 2009 - 4:58 AM

alright. that's scared me of the loudness. If were at that level, very soon will...... hehehe

Posted by: Hafkai Jan 31, 2009 - 10:39 AM

I finally got the car back and it runs great, the exhaust is relatively quiet but sounds wonderful. The E-manage works great but i have to do some settings till ignition and injection are perfect.. still get some engine knock but not as bad as with the old spark plugs. I just did a short test drive on the Autobahn smile.gif i never was that fast on >110mph and the car still pulls very hard, but my clutch decided to die and started to slip real bad.... i'll order a Exedy Stage 2..
short video of 2. - 3. gear, the clutch gripped but the wheels are spinning in 2. gear http://www.youtube.com/watch?v=-t8JA9D12-M&feature=channel_page

Posted by: normality78 Feb 1, 2009 - 6:37 AM

keep it coming.....

Posted by: eggman40 Feb 11, 2009 - 3:50 AM

man that is a GREAT install, i love how clean you installed everything. Especially with the small space your working with.

I would however try and maybe wrap the manifold and the first 2ft of the charge pipe with some heat wrap. that should help a little in keeping the heat from spreading in the engine bay, and more imporatantly the radiator. Ive never seen an exhaust pipe so close to the radiator, Id be a bit a concerned about the radiator breaking at a track day.

Either way, great job biggrin.gif

Posted by: WH95TE Feb 27, 2009 - 10:48 PM

everything looks great. good job

Posted by: Hafkai Apr 20, 2009 - 4:37 AM

I went to the track yesterday and the engine seems to like the boost wink.gif, no bigger problems at all, the oil temp was always below 120°C (~250°F) and exhaust gas temp peaked at 930°C (1700°F) @ 6200rpm. The water got a little bit hotter than usual but not too much.
The stock clutch is still in an holds the boost without problems... i'm a little bit astonished about this.

I got a video of the fastest lap.. cam position sucks but i love the engine sound wink.gif http://www.youtube.com/watch?v=EilCgRJxIYM
I was able to drop the lap times from 2:30 to 2:21 and this with bad tires...

Posted by: presure2 Apr 20, 2009 - 5:43 AM

QUOTE (Hafkai @ Apr 20, 2009 - 4:37 AM) *
I went to the track yesterday and the engine seems to like the boost wink.gif, no bigger problems at all, the oil temp was always below 120°C (~250°F) and exhaust gas temp peaked at 930°C (1700°F) @ 6200rpm. The water got a little bit hotter than usual but not too much.
The stock clutch is still in an holds the boost without problems... i'm a little bit astonished about this.

I got a video of the fastest lap.. cam position sucks but i love the engine sound wink.gif http://www.youtube.com/watch?v=EilCgRJxIYM
I was able to drop the lap times from 2:30 to 2:21 and this with bad tires...

1700*F is VERY hot.
be carefull with temps that high, your dangerously close to melting somthing. wink.gif

Posted by: Hafkai Apr 20, 2009 - 6:31 AM

Most of the time the egt is between 1300-1600°F but it can rise to 1650-1700 on the long straight..
It usualy peaks at 1630°F ... 1690°F was the highest i've seen so far.

Posted by: Hafkai Nov 9, 2009 - 9:25 AM

After about 7k miles the engine still runs great, i did a http://i124.photobucket.com/albums/p33/Hafkai/kompressionsmessung2010.jpg some weeks ago with ~190psi on all cylinders. The 7A really can take some abuse.. over 200 miles or 15 turns at the circuit without any problems, even at over 90°F ambient temperature.
The engine gets 10psi boost at all day driving and 7-9psi at the track, depending on the weather thanks to boost creep at low temps....
Oil consumption is a little bit high with almost 1L/1000km... but it could be worse wink.gif
The fuel consumption is not bad with ~27 mpg overall and 20 mpg at the circuit.

I got a short video from the Autobahn, testing 100-200 km/h acceleration at 10psi http://www.youtube.com/watch?v=YpwiK16gnyo

Posted by: SwissFerdi Nov 9, 2009 - 10:35 AM

Awesome man, awesome...this thread is inspiration for me. biggrin.gif

What have you done to the internals? Very sorry, I don't remember from the first time reading.

Posted by: Hafkai Nov 9, 2009 - 2:50 PM

QUOTE (SwissFerdi @ Nov 9, 2009 - 4:35 PM) *
What have you done to the internals? Very sorry, I don't remember from the first time reading.

The engine is completely stock, thats why i stop at 10psi.

Posted by: SwissFerdi Nov 9, 2009 - 3:21 PM

Interesting. OOBE said that 8 PSI was the max on stock internals. No issues whatsoever though?

Posted by: Hafkai Nov 9, 2009 - 3:55 PM

No issues at all, it depends on the injection and especially the ignition tuning how much a 7A will handle without braking something. I tuned my 7A to run with an afr of 11,5:1 at full boost and retarded the timing a lot. It's absolutely important to watch engine knock while tuning.
8 psi is pretty safe on a good tuned 7A, 10 psi is the max i would give a stock engine over a longer period of time, maybe 12-13 psi with an water injection.
If you want to go higher you have to lower the compression and get some stronger internals...

Posted by: OOBE Nov 9, 2009 - 4:21 PM

QUOTE (SwissFerdi @ Nov 9, 2009 - 2:21 PM) *
Interesting. OOBE said that 8 PSI was the max on stock internals. No issues whatsoever though?

WTF? I NEVER said that 8 PSI was the max on stock internals. I've had mine to 15 PSI. laugh.gif

The "mechanical engineer" guy was the one that said that. I was the one that broke that myth here years ago about the 7A-FE not being able to handle more than 7 PSI.

Posted by: SwissFerdi Nov 9, 2009 - 5:06 PM

QUOTE (Hafkai @ Nov 9, 2009 - 3:55 PM) *
No issues at all, it depends on the injection and especially the ignition tuning how much a 7A will handle without braking something. I tuned my 7A to run with an afr of 11,5:1 at full boost and retarded the timing a lot. It's absolutely important to watch engine knock while tuning.
8 psi is pretty safe on a good tuned 7A, 10 psi is the max i would give a stock engine over a longer period of time, maybe 12-13 psi with an water injection.
If you want to go higher you have to lower the compression and get some stronger internals...


I do know stronger internals are eventually necessary, I just thought that point was past 8 PSI.

QUOTE (OOBE @ Nov 9, 2009 - 4:21 PM) *
WTF? I NEVER said that 8 PSI was the max on stock internals. I've had mine to 15 PSI. laugh.gif

The "mechanical engineer" guy was the one that said that. I was the one that broke that myth here years ago about the 7A-FE not being able to handle more than 7 PSI.


OOBE, you lied to me! wink.gif Okay, good then. What I'm really looking for is not necessarily a max, but a good point for a DD. What do you run daily?

So both of you guys, push the hell out of your engines so Ferdi has plenty of study material!

Posted by: Hanyo Nov 9, 2009 - 5:18 PM

QUOTE (Hafkai @ Nov 9, 2009 - 6:25 AM) *
After about 7k miles the engine still runs great, i did a http://i124.photobucket.com/albums/p33/Hafkai/kompressionsmessung2010.jpg some weeks ago with ~190psi on all cylinders. The 7A really can take some abuse.. over 200 miles or 15 turns at the circuit without any problems, even at over 90°F ambient temperature.
The engine gets 10psi boost at all day driving and 7-9psi at the track, depending on the weather thanks to boost creep at low temps....
Oil consumption is a little bit high with almost 1L/1000km... but it could be worse wink.gif
The fuel consumption is not bad with ~27 mpg overall and 20 mpg at the circuit.

I got a short video from the Autobahn, testing 100-200 km/h acceleration at 10psi http://www.youtube.com/watch?v=YpwiK16gnyo



awesome look at that odometer move!

Posted by: OOBE Nov 9, 2009 - 5:52 PM

Ferdi,

With good tuning, 10 PSI on a good size turbo is nothing for this engine. You can run it daily. Even with the piston I hurt in the dyno, I was still boosting 15 PSI daily until the car overheated because of a failing radiator fan last week. The broken piston never got more hurt than what it was when I overboosted 18 PSI at the dyno, which is when it broke. The dyno read 222 WHP when the piston broke and I wasn't even on WOT. Who knows if the engine saw over 250 horses. The dyno read that, but the engine might've made way more. tongue.gif That's asking a lot. These are replacement pistons, so they might be weaker than Toyota pistons.

Remember that different turbos give you different power per pound of boost, and the weather conditions affect power A LOT, which is a very important fact that most people forget or fail to realize. In my case, just one PSI in the lower boost range on my turbo counts for ten wheel horsepower according to the dyno, and that's on 85 degree weather at night with a lot of humidity. I might get more on a cool day, which never happens in this island. I also have a bigger turbo, custom intake manifold and bigger throttle body...and also a more efficient intercooler with a horrible two PSI pressure drop. These items were not installed last time I dynoed, so I cannot compare the numbers. Everything changed. Who knows how much these items helped the engine or took away. I couldn't baseline unfortunately.

At 15 PSI, I'm probably getting a bit more than ten wheel horsepower per pound of boost, since the turbo is in its sweet spot on higher boost. Taking this into consideration and given the acceleration rate and how the car feels, if I follow that 10 WHP/PSI ratio, who knows if I'm probably at 250 WHP as of now...ignoring that the head is warped and that the piston is hurt. laugh.gif It's very possible, since the AFR stayed religiously the same from 7 PSI to 18 PSI and the power was being made consistently. biggrin.gif

If it wouldn't have overboosted, it wouldn't have broke a piston and I ASSUME I would be around that power level, give or take. A smaller turbo will give you less obviously. So after my experience, I can say that with a good tune, you can boost a bitty more than 200 WHP daily with no problems. smile.gif

Posted by: SwissFerdi Nov 9, 2009 - 5:58 PM

QUOTE (OOBE @ Nov 9, 2009 - 5:52 PM) *
With good tuning, 10 PSI on a good size turbo is nothing for this engine. You can run it daily. Even with the piston I hurt in the dyno, I was still boosting 15 PSI daily until the car overheated because of a failing radiator fan last week. The broken piston never got more hurt than what it was when I overboosted 18 PSI at the dyno, which is when it broke...about 230 WHP...which yields about 250 or more to the engine sicne this is an auto tranny. That's asking a lot. These are replacement pistons, so they might be weaker than Toyota pistons.

Remember that different turbos give you different power per pound of boost, and the weather condiions affect power A LOT...something that most people forget or fail to realize. In my case, just one PSI on my turbo counts for ten wheel horsepower, and that's on 85 degree weather at night with a lot of humidity. I might get more on a cool day. A smaller turbo will give you less power per pound of boost. So after my experience, I can say that with a good tune, you can boost a bitty more than 200 WHP daily with no problems.


That's great to hear. 200 WHP would be PLENTY for me, especially coming from...80ish WHP? laugh.gif Realistically, I'd like to say I'll be able to work on the engine once I start this turbo install...but more than likely, I'll still need to learn. Simplistically, I'd like to bolt the stuff on and get it tuned to a reliable standpoint for DD where I won't have any problems. I do want my money's worth in power right away, obviously.

Posted by: OOBE Nov 9, 2009 - 7:49 PM

Well, the most important thing is to find a good tuner, and either use an e-Manage, or an AEM FIC, or better yet, a stand-alone EMS, because you NEED to be able to control timing if you want the engine to last. I've broken a piston three times in six years. The first two times were because of detonation, not boost level or leaning out. This engine advances timing a boatload when accelerating. You will not believe it. I wish I would've recorded when my tuner took timing readings with a very expensive digital timing light. It was unreal and we were surprised that the engine lasted through all that abuse with such advanced timing throughout these years. By the way, I just sold my e-Manage last week. It worked awesome, but I need more control of the engine because I'm aiming for good numbers now since I'm going with forged internals. biggrin.gif

Posted by: SwissFerdi Nov 9, 2009 - 8:02 PM

I'd love to find somebody local that knew their way around a 7A-FE, or at least a turbo'd version of a Japanese 4-banger...my mechanic might have a hookup though, or know himself actually. I imagine those systems are pretty expensive? Well worth it though, obviously.

So basically, if the timing's off, the spark won't go off relative to the correct piston position and it'll just run like crap?

Posted by: OOBE Nov 9, 2009 - 8:46 PM

The spark will go off regardless, and there is no such thing as correct piston position. It depends on the engine and what you want to do with it. The point is that if the timing is too advanced, you'll get detonation. Detonation kills engines inside. There are different kinds of detonation. That's why you need high octane fuel or meth/water injection to run high boost. No need for someone to know about 7A-FE engines. My tuner is a 3S-GTE expert, but he has never touched a 7A-FE before mine. It's all about knowing the principles of tuning.

Posted by: SwissFerdi Nov 9, 2009 - 8:56 PM

Okay. I was just thinking in relation of the piston in the chamber moving toward the spark or away from it...if that makes sense.

Posted by: CelicaST_CALI Nov 9, 2009 - 9:03 PM

Detonation would be the the spark igniting the mix b4 the piston is a TDC(top dead center)...thus teh crank forcing the piston up and the mix forcing it down(bad mix frown.gif )

Posted by: Hafkai Nov 10, 2009 - 4:58 AM

QUOTE (CelicaST_CALI @ Nov 10, 2009 - 3:03 AM) *
Detonation would be the the spark igniting the mix b4 the piston is a TDC(top dead center)...thus teh crank forcing the piston up and the mix forcing it down(bad mix frown.gif )

The mixture is always ignited before TDC wink.gif, detonation occurs when the mixture is very hot and pressure rises extremely fast in the cylinder due to a to much advanced ignition timing, this ignites small parts of the mixture.
Pre-Ignition would be the really bad thing thats forcing the piston down when it want's to go up...

Posted by: CelicaST_CALI Nov 10, 2009 - 11:33 PM

well i ment wayyy before haha...Detonation=heat...pre-ignition=timing

Posted by: SwissFerdi Nov 11, 2009 - 1:07 AM

Hafkai, another question...you're running the stock transmission right? I'd like to do a manual swap before I turbo, and I'm wondering if the ST's C52 (?) will hold the power, or if I should just get the GT's S54.

Posted by: CelicaST_CALI Nov 11, 2009 - 1:11 AM

Ferdi,doc told me he had a 4agze with a c52 and 225 running through it fine..

Posted by: GMan Nov 11, 2009 - 10:35 AM

> Nov 9, 2009 - 8:02 PM
> SwissFerdi
> '97 ST Hatchback
> From Fort Myers, FL
> I'd love to find somebody local that knew their way around a 7A-FE, or at least a turbo'd version of a Japanese 4-banger...

We'd All love to find a professional to do it.

> So basically, if the timing's off, the spark won't go off relative to the correct piston position and it'll just run like crap?

Learn to tune Yourself ?
www.efi101.com

How far away is Port Charlotte ?

EFI-101
Fundamentals of High Performance Engine Tuning
Using Aftermarket Electronic Fuel Injection
Port Charlotte, FL (Relentless RPM)
http://www.efi101.com/schedule.php?cat=EFI&country=USA

Regards;

Posted by: FunkySR Nov 11, 2009 - 1:56 PM

OOBE, i've only taken 1 degree per psi of boost. I'm running at 9 psi.

Posted by: SwissFerdi Nov 11, 2009 - 4:05 PM

QUOTE (GMan @ Nov 11, 2009 - 10:35 AM) *
Learn to tune Yourself ?
www.efi101.com

How far away is Port Charlotte ?

EFI-101
Fundamentals of High Performance Engine Tuning
Using Aftermarket Electronic Fuel Injection
Port Charlotte, FL (Relentless RPM)
http://www.efi101.com/schedule.php?cat=EFI&country=USA

Regards;


Appreciate it, but $500 for two days of class? Holy crap!

Posted by: Culpable04 Nov 12, 2009 - 12:14 PM

for someone with an EMS on their vehicule and a good basic acknowledge of tuning, those courses make a lot of sense and are not pricey at all.

just to tune your frteshly installed EMS will cost you around 700 depending on the tuner / shop you go to.


Posted by: SwissFerdi Nov 12, 2009 - 12:17 PM

QUOTE (Culpable04 @ Nov 12, 2009 - 12:14 PM) *
for someone with an EMS on their vehicule and a good basic acknowledge of tuning, those courses make a lot of sense and are not pricey at all.

just to tune your frteshly installed EMS will cost you around 700 depending on the tuner / shop you go to.


...holy ****.

Posted by: Culpable04 Nov 12, 2009 - 3:56 PM

http://www.evans-tuning.com/rates_aem.html

Posted by: SwissFerdi Nov 12, 2009 - 4:03 PM

That is crazy...I had no idea. This is why I'm researching a few years ahead of time...thanks man!

Now, would this also be necessary on a 3S-GTE swap?

Posted by: OOBE Nov 14, 2009 - 12:22 PM

QUOTE (FunkySR @ Nov 11, 2009 - 11:56 AM) *
OOBE, i've only taken 1 degree per psi of boost. I'm running at 9 psi.


Well, my mechanic/tuner refuses to have an engine blow because of detonation. He's too proud and people here talk smack with a quickness if you screw up. He doesn't trust a piggyback, so he went really rich and safe on my tune since I'm on stock internals. The timing was retarded to like last year, LOL, and I still made good power. smile.gif He said that with forged internals and the Microtech LT10s, which is what he runs in his car, he will feel safe and be able to run a leaner mixture and also not retard timing so much. Right now he has the fastest MR2 in the island...with a stock head to boot. He knows his stuff. biggrin.gif

QUOTE (SwissFerdi @ Nov 12, 2009 - 2:03 PM) *
That is crazy...I had no idea. This is why I'm researching a few years ahead of time...thanks man!

Now, would this also be necessary on a 3S-GTE swap?


On ANY engine. And yeah, tuning is expensive. Here in the island the cheapest I've seen is $300, which is what my tuner charges. He charges less to me because I helped him with something when we met, so now he gives me good prices.

Posted by: SwissFerdi Nov 14, 2009 - 2:33 PM

Alright. Well, I guess it is money well spent. I know you did two turbo setups, and a tune for each I'm guessing, so do you think you would have spent less than a 3S-GTE swap if you had done only a single setup and single tune? Without any mods not absolutely necessary to turbo'ing, of course.

Posted by: Hafkai Nov 29, 2009 - 2:28 PM

QUOTE (SwissFerdi @ Nov 11, 2009 - 7:07 AM) *
Hafkai, another question...you're running the stock transmission right? I'd like to do a manual swap before I turbo, and I'm wondering if the ST's C52 (?) will hold the power, or if I should just get the GT's S54.

Yes i have a stock C52, the tranny seems to have no problem with turbo power. I only got some problems with my synchronizers but thats due to the harsh shifting on the track.

Btw... i got a little winter project..

I just test-fitted everything to check the clearance, seems to fit with the 16 inch wheels.

Posted by: Culpable04 Nov 30, 2009 - 2:24 PM

what are the specs ( offset specially ) of your wheels ?

I have the same brake set-up but I needed 15 mm spacers to clear my wheels.
what disc did you use on your set-up ?

I used Cadillac catera

Posted by: Hafkai Nov 30, 2009 - 3:09 PM

The wheels are 16x7 ET35, the brake discs are stock Toyota parts for the ST205.

Posted by: Hafkai Dec 5, 2009 - 10:19 AM

Another Autobahn video wink.gif, this time at about 12psi, the boost drops a little bit over 5500rpm and i think the T25 can't give much more than this at top end.... but i'm pretty happy with the result.

http://www.youtube.com/watch?v=5zS5Xk_vXfM

Posted by: Hafkai Feb 15, 2010 - 5:27 PM

Got some new injectors.. SARD 650cc/min



The reason for those big injectors is E85, i'm still tuning the e-manage but so far the engine runs really great with this stuff.

Posted by: presure2 Feb 15, 2010 - 5:31 PM

QUOTE (Hafkai @ Feb 15, 2010 - 5:27 PM) *
Got some new injectors.. SARD 650cc/min



The reason for those big injectors is E85, i'm still tuning the e-manage but so far the engine runs really great with this stuff.

NIIIICCEE!! bet those wernt cheap at all!
some of the guys on mr2oc have been having great results with E85, hope to see you have some too!

Posted by: OOBE Feb 15, 2010 - 5:40 PM

Keep us updated, man. I'm no longer in the 7A-FTE game but I will never lose my love for the engine. biggrin.gif I still have mine sitting in my garage. I don't want to sell it. I want to install it in another car.

Posted by: normality78 Apr 12, 2010 - 3:28 AM

QUOTE (Hafkai @ Nov 29, 2009 - 2:28 PM) *
Yes i have a stock C52, the tranny seems to have no problem with turbo power. I only got some problems with my synchronizers but thats due to the harsh shifting on the track.


Is there anyway to make the synchronizers stronger?

Posted by: Hafkai Apr 15, 2010 - 5:51 PM

QUOTE (normality78 @ Apr 12, 2010 - 10:28 AM) *
Is there anyway to make the synchronizers stronger?

I don't think there is some way to make synchronizers stronger, the only way to prevent them from getting destroyed is to shift properly wink.gif ...

After over 1000 miles on E85 the engine still runs great and i completely retuned the E-manage to use the possibilities of this fuel.
2 weeks ago i went to the racetrack for the first time this year and with ~10psi boost instead of 8psi like last year. I really love E85.. no knock and the engine stays a little bit cooler than with regular fuel, perfect for track racing.

I currently boost about 12,5psi with my daily drive setup without problems but i won't go any further before the engine got rebuild.

Posted by: SwissFerdi Apr 15, 2010 - 5:57 PM

thumbsup.gif

What are the plans for the rebuild?

Posted by: Hafkai Apr 16, 2010 - 6:08 AM

QUOTE (SwissFerdi @ Apr 16, 2010 - 12:57 AM) *
What are the plans for the rebuild?

Some h-beam rods that i already got, Wiseco pistons (9:1 compression) and the basic stuff to rebuild an engine wink.gif .. and maybe a GT28R turbo if i got some money left wink.gif.

Posted by: mariosdarkworld Apr 16, 2010 - 4:26 PM

How is the pull with the 650cc injectors? Does that turbo only hit like 15 psi max? Do you have a write up on some of this besides what you have as a part list in the begging? Have you tried pump gas with those new injectors? Sorry for all the questions I'm still learning lol

Posted by: Hafkai Jun 6, 2010 - 3:56 PM

QUOTE (mariosdarkworld @ Apr 16, 2010 - 11:26 PM) *
How is the pull with the 650cc injectors? Does that turbo only hit like 15 psi max? Do you have a write up on some of this besides what you have as a part list in the begging? Have you tried pump gas with those new injectors? Sorry for all the questions I'm still learning lol

The injectors don't make any noticeable difference, you just got more room left for power wink.gif and no i don't have another write up.

I did some performance test runs with http://www.racechrono.com/ together with a 5hz GPS receiver, maybe not 100% accurate but it shows roughly what's possible. Max boost was 11,5psi.



Posted by: Hafkai Jun 17, 2010 - 1:25 PM

Today i went to a dyno and i'm really happy with the results


Posted by: RoyO Jun 17, 2010 - 2:07 PM

Very good results!! tongue.gif

Posted by: celica74 Jun 23, 2010 - 5:57 PM

QUOTE (SwissFerdi @ Nov 9, 2009 - 5:06 PM) *
QUOTE (Hafkai @ Nov 9, 2009 - 3:55 PM) *
No issues at all, it depends on the injection and especially the ignition tuning how much a 7A will handle without braking something. I tuned my 7A to run with an afr of 11,5:1 at full boost and retarded the timing a lot. It's absolutely important to watch engine knock while tuning.
8 psi is pretty safe on a good tuned 7A, 10 psi is the max i would give a stock engine over a longer period of time, maybe 12-13 psi with an water injection.
If you want to go higher you have to lower the compression and get some stronger internals...


I do know stronger internals are eventually necessary, I just thought that point was past 8 PSI.

QUOTE (OOBE @ Nov 9, 2009 - 4:21 PM) *
WTF? I NEVER said that 8 PSI was the max on stock internals. I've had mine to 15 PSI. laugh.gif

The "mechanical engineer" guy was the one that said that. I was the one that broke that myth here years ago about the 7A-FE not being able to handle more than 7 PSI.


OOBE, you lied to me! wink.gif Okay, good then. What I'm really looking for is not necessarily a max, but a good point for a DD. What do you run daily?

So both of you guys, push the hell out of your engines so Ferdi has plenty of study material!






Pressure and volume of air are a completely different thing. You can run a small turbo and boost 12, 14, 16psi all day long, yea itll spool up insanely fast. But if you run a bigger turbo and boost 6, 8, 10psi (same power as small turbo boost) it wont spool as fast. Yea that guy that told you that was correct to some extent, that extent is how big or small your turbo is.

I have a 94 st with a newly swapped 95 7afe in it with only 124k miles. 4afe turbo kit sitting up in my room (yes 4afe exhaust and 7afe are the same) just waiting on injectors and fuel pressure regulator and im hiding in my garage for a weekend to install it. Anyone know if brown top (93-96 325cc 2jzge) injectors will work fine? And i need a good piggyback or way of tuning. Any cheap ideas?

Posted by: Hafkai Jun 25, 2010 - 3:55 AM

QUOTE (celica74 @ Jun 24, 2010 - 12:57 AM) *
And i need a good piggyback or way of tuning. Any cheap ideas?

Cheap and good doesn't work wink.gif .. the e-manage blue would be cheap but not the best choice, the e-manage ultimate is more expensive but you can tune the engine pretty safe. The best way would be a standalone but that would be extremely expensive and hard to tune.

I got some nice parts waiting to get in the engine, hopefully i'm able to rebuild the engine before winter smile.gif


Posted by: SwissFerdi Jun 25, 2010 - 9:53 AM

Ooooh...upgraded pistons, rods, and new gaskets and belts...I like it!

Posted by: celica74 Jun 26, 2010 - 9:32 AM

QUOTE (Hafkai @ Jun 25, 2010 - 4:55 AM) *
QUOTE (celica74 @ Jun 24, 2010 - 12:57 AM) *
And i need a good piggyback or way of tuning. Any cheap ideas?

Cheap and good doesn't work wink.gif .. the e-manage blue would be cheap but not the best choice, the e-manage ultimate is more expensive but you can tune the engine pretty safe. The best way would be a standalone but that would be extremely expensive and hard to tune.

I got some nice parts waiting to get in the engine, hopefully i'm able to rebuild the engine before winter smile.gif






Anyone got any good ideas on injectors? Was looking into brown tops from a 7mge, anything seem to work better?

Posted by: normality78 Oct 13, 2010 - 4:59 AM

Hafkai bro,
I've sold my previous 7afte (stock engine, wrx td04-13t, emanage blue, Ron97) to my friend. On my hand, im boosting 1.1bar for 2 years and now with him another 2 years. So far no issue except head gasket burnt once.

now im going to go for it again except with IHI Vf35 turbo and standalone haltech sprint 500. Will push to 1.3bar and see how it go. smile.gif since you're going to rebuilt, why not push it to max?

Posted by: Hafkai Oct 16, 2010 - 7:45 AM

Sadly it's to late to push the stock engine to max kindasad.gif .. last week a rod bearing failed, now i got a broken rod and a big hole in the block..... looks like a oil problem. I already got a new block and most of the stuff i need to completely rebuild it, i just need new bearings.

But the engine can handle a good amount of power without problems. I was trackracing the last 2 years with the turbo, this year with about 230HP and over 300Nm, i just should have changed the bearings wink.gif

Posted by: malpaso Oct 16, 2010 - 11:47 AM

I had my old 7AFTE tuned to the limits on OEM internals as well so this project is for me real nostalgia... I hope your car will be running again soon and luckily we meet in Poland on Pan European Celica Meeting next year.

Posted by: Hafkai Nov 14, 2010 - 4:11 PM

After taking the old engine apart i found out that the bearing wasn't the cause of the thrown rod, it looks like the spark plug overheatet extremely, the electrode began to glow and i got the worst of it all... pre-ignition. I'm not shure what caused the plug to overheat, i don't think it was a fuel problem but i will let the injectors get checked.

Here is a pic of the spark plug and some of the rest of the engine:









The new block is getting machined this week and a new cylinderhead is allmost done, i just have to polish the combustion chambers and finish the ports.










Posted by: Johnnyny Nov 14, 2010 - 5:06 PM

wow that plug looks horrible but im glad ur continuing the build

Posted by: Hafkai Dec 25, 2010 - 5:50 AM

The new block is ready and the head just needs to be put together.





Finished exhaust port





Posted by: enderswift Jan 2, 2011 - 10:47 PM

i cant wait to see the results

Posted by: jeffrosie Jan 3, 2011 - 7:37 AM


Been folowing this with great interest. Hope you find out what caused that plug to melt and looks like that new forged engine will give you even more power with the biger turbo and a little more boost.

Posted by: 97celica_st Jan 13, 2011 - 9:29 AM

Where did you find the forged pistons and rings? and is it the stock crankshaft?

Posted by: Hafkai Jan 13, 2011 - 11:40 AM

You got a PN about the pistons smile.gif

The crankshaft is still the stock one, there are no alternatives anyway wink.gif but this part would be the last to fail on this engine..

Posted by: Hafkai Jul 8, 2011 - 5:29 PM

The project is still alive but everything takes much longer than expected.. the new engine is ready to get in the car, the stock ecu and the e-manage ultimate got replaced by a EMS 6860. Hopefully the engine will be in the car next week, a new rediator + Spal fan will follow and some modifications to the exhaust and intercooler piping are needed to fit the slightly larger T28 turbo.

Some pics from the last months:


















Posted by: malpaso Dec 5, 2011 - 8:44 AM

Any update? smile.gif

Posted by: kurt95gt Dec 5, 2011 - 1:53 PM

QUOTE (Hafkai @ Jul 8, 2011 - 5:29 PM) *

boobs!!!

Posted by: RabidTRD Dec 5, 2011 - 3:30 PM

QUOTE (kurt95gt @ Dec 5, 2011 - 1:53 PM) *
QUOTE (Hafkai @ Jul 8, 2011 - 5:29 PM) *

boobs!!!

Omg how did you see that? Lmao! ADHD much?

Posted by: Hafkai Dec 5, 2011 - 3:44 PM

QUOTE (malpaso @ Dec 5, 2011 - 2:44 PM) *
Any update? smile.gif

Nothing too exciting.. the engine is in the car with the T28 turbo, i got everything done to start the engine but had lots of trouble with the ignition.
The engine fired right up but died immediately, everytime ... i played with the fuel map, turned the distributor in every position but the engine wouldn`t run.
Here's a short video: http://vimeo.com/27783812

I decided to completely remove the old ignition system and build me a coil on plug system. I will use ahttp://i124.photobucket.com/albums/p33/Hafkai/Motor/DSC_2251.jpg as crank angle(24 instead of 4 teeth) and sync pickup. The coils are from Bosch (part#: http://www.bosch-motorsport.de/en-US/literature/en-US/0221504024_DataSheet_enUS_T7730639627.pdf), since they're dumb coils withouh build in igniters i have to use an external (part# http://www.bosch-motorsport.de/en-US/literature/en-US/0227100211_DataSheet_enUS_T6821227531.pdf)
Those coils fit quite well, the only problem could be the hood since they're connectors face in that direction ......



I hope i'll have some time soon to install this stuff.

QUOTE (kurt95gt @ Dec 5, 2011 - 7:53 PM) *
boobs!!!

laugh.gif .. it's really hard to make pics without them in this garage wink.gif

Posted by: kurt95gt Dec 5, 2011 - 4:26 PM

Better question is how don't you notice a topless girl in the pic it's tight there lol
guess I look to close at pics

Posted by: malpaso Dec 6, 2011 - 4:18 AM

QUOTE (Hafkai @ Dec 5, 2011 - 9:44 PM) *
I decided to completely remove the old ignition system and build me a coil on plug system. I will use ahttp://i124.photobucket.com/albums/p33/Hafkai/Motor/DSC_2251.jpg as crank angle(24 instead of 4 teeth) and sync pickup. The coils are from Bosch (part#: http://www.bosch-motorsport.de/en-US/literature/en-US/0221504024_DataSheet_enUS_T7730639627.pdf), since they're dumb coils withouh build in igniters i have to use an external (part# http://www.bosch-motorsport.de/en-US/literature/en-US/0227100211_DataSheet_enUS_T6821227531.pdf)
Those coils fit quite well, the only problem could be the hood since they're connectors face in that direction ......

Damn... what a progress! I had on my old 7AFTE also as option ready coils. They fit well and were from Skoda smile.gif



Never used them so can not give you feedback for those...

Posted by: Hafkai Jun 27, 2013 - 2:21 PM

Well... super slow progress but i'm still working on the car... i finally found a garage with decent space so the car doesn't have to stand outside on some else`s property all the time.



The first thing i did was making space to rework most of the electrical stuff i build in over the years, lots of crap got ripped out there... now all the wires are nicely installed and things like fuses are there too.. woohoo



In all the time between doing nothing and doing even more nothing i decided that this car won't need a radio and most of the gauges got a new place.



Oh and finally.. the engine is running, needs lots of tuning but it is alive smile.gif

http://www.youtube.com/watch?v=jD7AKhuGy5I and after some tuning http://www.youtube.com/watch?v=BmVsgvuZRlg wink.gif


Posted by: The_enD Jun 27, 2013 - 3:44 PM

Love everything you've done so far. Damn, how much I want to turbo my 7A-FE...

Posted by: Box Jun 27, 2013 - 4:26 PM

Inspiring, yet at the same time it makes me realize how much of a bitch it'd be to do.

Also, damn Ferdi it takes you forever to get anything done. tongue.gif

Posted by: SwissFerdi Jun 27, 2013 - 7:47 PM

QUOTE (Box @ Jun 27, 2013 - 5:26 PM) *
Also, damn Ferdi it takes you forever to get anything done. tongue.gif


???

Kai, that gauge setup is absolutely brilliant. Looks as beautiful as it is functional.

Posted by: Box Jun 27, 2013 - 8:21 PM

Almost 4 years to swap transmissions, come on now. tongue.gif

Posted by: SwissFerdi Jun 27, 2013 - 8:33 PM

Well yes, you are correct in a sense, but how that's related to this thread...

Posted by: Box Jun 27, 2013 - 9:45 PM

QUOTE (SwissFerdi @ Jun 27, 2013 - 8:33 PM) *
Well yes, you are correct in a sense, but how that's related to this thread...

You posted earlier in this thread about doing such, page 3 I believe. That's the only reason I even knew you were planning on it for so long. tongue.gif

Posted by: travisxcore Jun 28, 2013 - 12:09 PM

This is page 3...

laugh.gif

I think that is the most awesome gauge cluster setup I've ever seen.

Posted by: Box Jun 28, 2013 - 12:55 PM

QUOTE (travisxcore @ Jun 28, 2013 - 12:09 PM) *
This is page 3...

laugh.gif

I think that is the most awesome gauge cluster setup I've ever seen.

Y u no read, this is page 6. tongue.gif

I agree, that's a very nice gauge setup. Except for now there's no music. frown.gif

Posted by: The_enD Jun 28, 2013 - 12:58 PM

Turbo spool.mp3 biggrin.gif

Posted by: kurt95gt Jul 11, 2013 - 7:53 AM

Nice gauge setup. Puts everything at a good level an aimed at you
Maybe you can squeeze a MP3 player in by the CIG lighter lol

Posted by: Hafkai Sep 30, 2013 - 12:52 PM

I finally got everything back together and the engine running good enough to take it for a ride.. after 3 years.. this really was exciting biggrin.gif
I did about 400miles in 5 days. No problems so far, no water or oil cunsumption, no smoke...

I haven't pushed the engine a lot but i did some 3. gear pulls and i think the engine will be nice when it's fully tuned and running high boost. For now i set the boost to 10psi (T28 turbo) and my 80-120km/h times where almost as fast as with the old T25 @ 14psi ...

Did a short video of a late test drive, nothing special but i love the look of all the gauges wink.gif ... http://www.youtube.com/watch?v=Q_wWNu9v7hc

And i got a nice set of new rims since the old 16" Ultraleggera didn't fit over the front brake without spacers...
Sparco Assetto Gara 7,5jx17 with Avon ZZR tires in 225/45.






Posted by: cheela Sep 30, 2013 - 1:53 PM

love it!

Posted by: Makabra Sep 30, 2013 - 2:38 PM

QUOTE (Hafkai @ Sep 30, 2013 - 1:52 PM) *
Did a short video of a late test drive, nothing special but i love the look of all the gauges wink.gif ... http://www.youtube.com/watch?v=Q_wWNu9v7hc


Looks ubercool biggrin.gif Reminds me of an airplane cockpit


Posted by: malpaso Oct 1, 2013 - 1:52 AM

wow... at last I can read news like this smile.gif. it is looking great (I love that view with both wheels in a line with body). thumbsup.gif thumbsup.gif thumbsup.gif

Posted by: Hafkai Oct 16, 2013 - 1:53 PM

I just made some pics of the car and i'm quite happy with the outcome... comments are welcome smile.gif














Posted by: The_enD Oct 16, 2013 - 1:54 PM


Posted by: enderswift Oct 16, 2013 - 9:15 PM

Best looking 7a I have ever seen

Posted by: malpaso Oct 17, 2013 - 2:47 AM

QUOTE (enderswift @ Oct 17, 2013 - 4:15 AM) *
Best looking 7a I have ever seen

sad to say (I had one my self)... but agree smile.gif. GREAT job!

Posted by: Hafkai Jan 13, 2014 - 5:52 PM

Small update... i bought a simple compression tester and this is the result: cylinder 1-4 : 190 | 188 | 187 | 186 psi ... I'm pretty happy with those numbers.

Then i build a scale to measure the corner weights of the car that is able to weigh up to 500kg (~1100lbs) since i wasn't able to find one thats affordable.
Surely not as precise as a professional corner weight scale but enough to get an idea of the cars weight distribution smile.gif









The only problem is that i only have one scale.... so i have to get all the other wheels on the same height and it takes some time to measure every corner... but im not doing this every month so it's ok wink.gif

Weights without driver and full tank of E85:

FL 745 lbs | FR 815 lbs / 63%

RL 485 lbs | RR 428 lbs / 37%

Total 2473 lbs

Weights with driver:

FL 813 lbs | FR 835 lbs

RL 555 lbs | RR 432 lbs

Total 2635 lbs

Posted by: Hafkai Jan 15, 2014 - 2:05 PM

Just finished another little winter project wink.gif started out with a ST202 rev counter i installed that was a little inaccurate.. searched a way to calibrate it and found out that you can alter the movement of the needle quite a bit. Enough to let it travel twice as much with the same rpms, or the opposite way with the speed indicator.

Doesn't look perfect but it works.. smile.gif



And a short video where i was testing the modified hardware with the old dials.

http://www.youtube.com/watch?v=LIYlkdgLK0Q

Posted by: BonzaiCelica Jan 15, 2014 - 4:40 PM

ha friggin awesome stuff didnt know you were on ethonal

Posted by: Hafkai Jan 21, 2014 - 3:30 PM

E85 is awesome, i will try to get some E100 for this season... no more crappy fuel that contaminates the good alcohol wink.gif .... just a little difficult to get..
And since my 650cc SARD injectors are getting a little bit to small for this stuff i will replace them with some far more modern Bosch EV14 980cc injectors.

Posted by: Hafkai Feb 10, 2014 - 5:03 PM

New fuel rail and injectors are ready, i just need some fittings and stuff to build a new fuel line from the stock filter to the rail.






Posted by: Poonicus Feb 16, 2014 - 2:56 PM

Tut die 7afte haben die Zündspule im Verteiler wie der 5sfe?

Es tut uns leid mein Deutsch ist einen kleinen rostig haha, mag meinen auto. XD

Posted by: enderswift Feb 16, 2014 - 5:19 PM

that is the sexiest 7a manifold I have ever seen O.O

Posted by: SwissFerdi Feb 17, 2014 - 2:55 PM

Great looking manifold, and I don't know how I missed it (and nobody else commented), but a center-mounted tacho! (!!!!!) That's fantastic! I love that look. Why the optimistic redline though?

Posted by: Hafkai Feb 17, 2014 - 4:49 PM

QUOTE (Poonicus @ Feb 16, 2014 - 8:56 PM) *
Tut die 7afte haben die Zündspule im Verteiler wie der 5sfe?

Es tut uns leid mein Deutsch ist einen kleinen rostig haha, mag meinen auto. XD

Haha not bad smile.gif .. and yes the stock 7a got the coil in the distributor, but not my 7a wink.gif

@ SwissFerdi

And i thought i'm the only one who likes that idea wink.gif .. i plan to install 266°/256° cams (the only option i got in germany) in the future, therefore the high redline. With stock cams theres no reason to rev that high, thats right.
A video of the tacho with the new dials, it's a bit more laggy than the stock tach due to the stronger spring on the speedo needle, but nothing too bad: http://www.youtube.com/watch?v=6iPEiSiuLEg

The new manifold is on the engine, build a AN6 fuel line to the stock filter, no leaks this time... and the engine is running really well with the new injectors. They're pretty loud but thats no problem, idle is a bit smoother and the throttle response seems to be a bit better.


Posted by: Hafkai Apr 15, 2014 - 2:05 PM

Back on the streets smile.gif ... https://www.youtube.com/watch?v=QjJLM6aARAc

Still have to do lots of tuning with the new injectors and my ST205 fuelpump seems to be maxed out... but i have a Aeromotive 340 ready to go in.
But for now i`m really happy how the engine performs.




Posted by: STlad Apr 15, 2014 - 4:09 PM

Pulling very nice there wink.gif Lot of respect for this Celica with all the work you've done on it wink.gif

Posted by: kormysh8 Apr 15, 2014 - 8:00 PM

WOW. Good work! Love every bit of this ST! 7ATFE powa!! Ever thought about shaving down some of the fins inside of the intake mani?

Posted by: Hafkai Apr 22, 2014 - 2:13 PM

Thanks for your comments smile.gif

@ kormysh8: not really, i don't think this would gain any power at all, the best solution would be a completely new intake manifold, but for now the stock on seems to be sufficient.

I finally went to the track yesterday, i was somewhat nervous and planned only to do some slow laps.... well... that was the plan ....

https://www.youtube.com/watch?v=7PZWNCFQrNA .... starting behind the ST205 was a bad idea... i just had to go WOT...

The suspension seriously needs a new setup... the car corners like a rwd without the corner exit grip .... very loose rear end, but lots of fun wink.gif ..
But even with the crappy traction i managed a top speed of 132mph on this track, faster than i thought.

Posted by: Syaoran Apr 30, 2014 - 2:48 PM

That was pretty good. A lot of tire squealing lol.

What's the Porsche brakes from?

Posted by: Hafkai Apr 30, 2014 - 3:21 PM

QUOTE (Syaoran @ Apr 30, 2014 - 9:48 PM) *
That was pretty good. A lot of tire squealing lol.

What's the Porsche brakes from?

Thanks! smile.gif ... i definitely need a LSD....
The calipers are from a preface 996 Turbo/GT3, the caliper brackets are custom made and the discs are stock ST205.

Posted by: SwissFerdi May 1, 2014 - 7:45 AM

QUOTE (Hafkai @ Apr 22, 2014 - 3:13 PM) *
The suspension seriously needs a new setup... the car corners like a rwd without the corner exit grip .... very loose rear end, but lots of fun wink.gif ..


Mine does the same, I don't think it's necessarily your suspension setup. When the rear of this car is stiffened it just likes to swing a bit, especially in a steady-state corner under trail-braking. I love it.

You were quick mate, very well done. Passed a lot of cars that technically should have been passing you.

Edit - LOL @ at the E30 around 7:30, he was trying so hard!

Posted by: Hafkai Jun 10, 2014 - 2:54 PM

Well...... crap .....



Always remember to use loctite on flywheel bolts.... btw.. does someone know if there are suitable ARP bolts for the 7A?

I'm not sure if they really got loose and the whole thing rattled itself to death or if the bolts simlpy failed.. but the marks from the bolt heads in the flywheel look like the thing was loose for some time...

Posted by: SwissFerdi Jun 10, 2014 - 3:01 PM

redface.gif

Scary! Any clutch damage?

Posted by: Hafkai Jun 10, 2014 - 3:37 PM

Nothing bad, just some scratches.



The worst part is the crankshaft....



I hope the mating surface can be fixed but it sucks to take half the engine apart.... it was running so good and everything was fine, goddamit mad.gif mad.gif

Posted by: Hafkai Jul 6, 2014 - 2:12 PM

I replaced the crankshaft with my old one from the first engine, had to get 2 new main bearings because the crank has different journal sizes and i replaced all rod bearings too. Still waiting for the ARP flywheel bolts and i got me a new clutch since the Exedy Stage 2 was slipping at 1,2bar boost.
The new one is a ACT XTSS, should hold up to 310ft/lbs... the Exedy was supposed to hold 261ft/lbs wich is pretty much the exact torque i had with 1,1bar.

Posted by: Hafkai Jul 7, 2014 - 3:09 PM

I finally got the ARP bolts (ARP# 203-2802), torqued them to 70ft/lbs (stock bolts 58ft/lbs) and this time with loctite....

ARP compared to stock bolts:





New clutch...



I got most stuff back together, just need to torque the transmission bolts and reinstall the IC piping. The clutch pedal is definitely stiffer compared to the Exedy Stage 2 but nothing to bad.

Posted by: Hafkai Jul 20, 2014 - 1:05 PM

Well... the ACT clutch is amazing, smooth engagement and seems to hold more torque than the Exedy Stage 2... maybe to much for my old transmission... years of track racing an a lot more power than stock resulted in a funny looking 3rd gear:



I replaced the transmission with a spare one i luckily had laying around, but i think i should start to look out for an alternative to the C52 ...

Posted by: enderswift Jul 20, 2014 - 8:34 PM

Man, you've got some bad luck lately. Kudos for not getting frustrated with the car!

Posted by: Hafkai Apr 25, 2015 - 4:02 AM

Long time since the last post... haven't done much on the car besides trying not to destroy something wink.gif ..

The only new things are some oil-/fuel catch tanks and a new air filter box, everything build from scratch.

Since my Aeromotive Stealth intank pump died after just about 2-3.000km i put the old ST205 pump back in and let her fill the catch tank, from there an external Bosch 044 feeds the engine.

The air filter box still needs a top cover since it's kinda illegal to run open air filters in germany .... but for now i leave it open, just love the sound wink.gif ....






Posted by: enderswift Apr 25, 2015 - 8:23 AM

Thats some really nice welding. good work

Posted by: SwissFerdi Apr 27, 2015 - 9:14 AM

My favorite 7A-FE. Beautiful. Real racecar.

Posted by: Hafkai May 3, 2015 - 12:02 PM

Thanks! smile.gif .. i'm really happy how the welds look too but i still need to practice a lot

I just made a little video while testing a new ECU setup:

https://www.youtube.com/watch?v=zfIHGawd7Tw

Posted by: Hafkai Jun 25, 2015 - 3:46 PM

Again some Videos... wink.gif ..

My little 7A vs my daily S4 B5 .. poor Audi...

https://www.youtube.com/watch?v=8BDnM7jfjGg

https://www.youtube.com/watch?v=tcGBhF-MgfU

https://www.youtube.com/watch?v=F3ZphoQLMAg

And a little Video made by a friend

https://www.youtube.com/watch?v=8sMpKEzkDIw

Posted by: Javicillo Mar 9, 2017 - 5:20 AM

QUOTE (Hafkai @ Jun 25, 2010 - 4:55 AM) *
QUOTE (celica74 @ Jun 24, 2010 - 12:57 AM) *
And i need a good piggyback or way of tuning. Any cheap ideas?

Cheap and good doesn't work wink.gif .. the e-manage blue would be cheap but not the best choice, the e-manage ultimate is more expensive but you can tune the engine pretty safe. The best way would be a standalone but that would be extremely expensive and hard to tune.

I got some nice parts waiting to get in the engine, hopefully i'm able to rebuild the engine before winter smile.gif




Where did you find the forged pistons and rings? What model or reference are they?

Posted by: Hafkai Mar 13, 2017 - 2:24 PM

QUOTE (Javicillo @ Mar 9, 2017 - 11:20 AM) *
Where did you find the forged pistons and rings? What model or reference are they?

You got a PN smile.gif

Quite some time since i posted something, i haven't done much last year, i finally installed a ST205 Spoiler i got for years waiting to get some paint.. and i removed the really old EMS 8860 ECU and replaced it with a Ecumaster EMU.





Well and last month i removed the cylinder head... i still have big problems with oil flowing through the crankcase ventilation port in the valvecover when driving at the circuit, blowby is definitely not the cause of this problem so it has to be something else...
I remembered that there are oil restrictors for 4a-ge engines that are placed in the oil port that goes to the head, and since the oil return holes in the head are really small and somewhat funny placed i thought i'll give it a try and put a restrictor in my block... i hope that this will solve my problem and i really hope the restriction is not to much and i get problems with sufficient oil pressure at the head tongue.gif

And the next thing i upgrade while the head is off are the camshafts, but i have to modify some things to make them work, the intake cams got 9,5mm lift wich doesn't sound like much but the 7A is not designed for that... i measured everything and it seems like the spring retainers are very likely to run into the valve stem seals and the springs may even bottom out so i'll have to modify the valve guides and i ordered new valve springs.

Hopefully i got all parts till the end of the month and the car will be ready in the next 3-4 weeks.

Posted by: 7afe_carina Mar 22, 2017 - 10:14 AM

You really are courageous with that oil restrictor biggrin.gif Is the OEM oil pressure sender on the 7AFE also in the head? Then you could check the pressure there with a sensor just to be sure that there is still enough pressure up top.
I wouldn't say that 9,5 mm lift isn't much on an 1.8 liter ;-)

Posted by: Hafkai Aug 31, 2017 - 12:40 PM

QUOTE
Is the OEM oil pressure sender on the 7AFE also in the head?

The pressure sender sits in the engine block next to the oil filter, but after over 1.000 miles i got no problem with the head so i think there's still enough oil pressure wink.gif

With the new cams in, the engine felt way better in higher rpms, revved pretty quick to 6500 rpm but still wasn't happy above that. The cams should be aggressive enough to rev way past 7000 without a problem so there must be something preventing a good flow.
So i started building a new intake using a ST185 throttle body, here are some pics:















And a short video of a 3rd gear pull, rev limiter is set at 7700rpm:

https://www.youtube.com/watch?v=WRI1ZIktgAU

The engine feels a little bit dull mid range since i lost some torque but it revs like crazy considering it's a 7A wink.gif ... and the gearing doesn't fit the engine anymore, 3. gear ends at 107 mph and 4. at 144 mph ... waaaay to long

Posted by: BonzaiCelica Sep 2, 2017 - 6:40 AM

you could just swap in the final drive from the c56 transmission. a 4.312 ratio. or better yet find a C160 transmission.


but great build. its so unique. are you still running that cold air box set up with new intake manifold??


Posted by: Hafkai Oct 31, 2017 - 1:18 PM

QUOTE (BonzaiCelica @ Sep 2, 2017 - 12:40 PM) *
but great build. its so unique. are you still running that cold air box set up with new intake manifold??

Thanks smile.gif .. the air box is still in and seems to be big enough and working quite well for now

The car finally was on a dyno and i'm very happy with the result, very nice torque curve and some good power regarding the old T28 turbo

1,1bar - 16psi


And a short 100-200km/h video

https://www.youtube.com/watch?v=ElviBFdqoRs

Posted by: Hafkai Aug 1, 2020 - 4:58 AM

Quite some time since my last post and a lot has been done to my Celica, the car was running really good with the 2017 setup but i couldnīt get any more out of the old T28 so in 2019 i decided to go with a new turbo. I planned to get an EFR for some time but i would have been a lot work to make it fit, so i decided to stay with Garrett and got me a GTX2860R GenII and it definitely was the best decision... awesome turbo and the sound is amazing bowdown.gif

Of course the C52 didnīt like it that much... i kept boost in 3. gear at about 16psi and raised it in 4. and 5. to about 21psi but i still managed to rip the 3rd gear appart just like my old transmission... so i started to search something else that will hold some power... of course a E58 was the way to go but impossible to get in germany, i luckily found one in Australia and he even shipped it to Germany. Meanwhile i put in another C52 so in can drive and raised the boost in 4. and 5. even more to about 26psi and barely used the 3rd gear at all wink.gif

I took the E58 apart to see what i got and was a little disappointed regarding the size of the gears, of course they are stronger than the C52 ones but i was hoping for something more trustworthy wink.gif ... here is a direct comparison left E58 / right C52:



Then i got the idea of mating a E154 ST205 transmission to the E58 bell housing wich should work in theory.... i found a E154f for even half the price the E58 cost me, took it apart and eveything was looking perfect, the gears are WAY stronger and should hold way more than my 7A will ever produce...





A nice LSD shouldnīt be missing in a build like this...



The mounts on the transmission had to be reworked to make all this fit but that wasnīt to much trouble, the clutch and axles were much more of a problem.... at first i tried to get a new clutch disc from ACT for my XTSS but they didnīt respond to me, so i contacted clutchmasters and they made me a custom clutch to fit the E154 spline, itīs a FX350 so still very daily drivable and holds quite some torque..
As for the axles i planned to get some custom made but that would have cost me a fortune here in Germany so i found a set of AW11 SC axles in the US.. not cheap either but it was the right decision, the outer joints even fit the AT200 hub i just had to fit ABS rings on them ... then i had the get some spacers for the inner joints made since the axles where a bit to short but it worked perfect in the end.

Other things i changed are the PCV catch can and the air filter housing, i was trying to fit a filter as big as possible and ended with a Lexus ISF filter.





I got some new gauge faces made to fit the engine better, rev limiter is set at 8100rpm.



Next step this year is a new intake manifold with slightly shorter runners with bigger diameter and a much bigger plenum.

And iīm building a new short block since the engine is blowing gas in the cooling system, at first i thought itīs the old cracked head so i build a new one last winter... but that didnīt fix the problem, even ARP head studs werenīt enough till i noticed that the deck was not flat.

I wasnīt on a dyno yet but the engine should make about 400-420bhp, maybe 340-350whp.

Posted by: Tigawoods Aug 1, 2020 - 9:39 AM

im glad its still running great and that you are improving it even more!!

Posted by: enderswift Aug 2, 2020 - 11:01 AM

Dude you are an inspiration

This whole project is amazing

Posted by: BonzaiCelica Aug 2, 2020 - 5:03 PM

ya definitely my favorite ST build.

so your using the 91-94 corolla GTZ transmission. i know the 1st generation scion tc has a e350 and that the shifts feel more secure than an s54.

have you any videos of your car on track?

Posted by: bloodMoney Aug 3, 2020 - 8:23 AM

This is nuts.

I love it.

Posted by: cheela Aug 4, 2020 - 12:20 PM

amazing! love this build!

Posted by: SwissFerdi Aug 4, 2020 - 9:27 PM

Fantastic. Good to see you are still active. I miss my 7A. kindasad.gif

Posted by: Hafkai Aug 22, 2020 - 8:56 AM

QUOTE (BonzaiCelica @ Aug 3, 2020 - 12:03 AM) *
have you any videos of your car on track?

No, nothing from a 1/4 mile and no circuit videos with this setup, but i wouldnīt try it with this setup right now, on a circuit iīm pretty sure something would overheat with the stock cooling system biggrin.gif .. and for a 1/4 mile i would need some better tires and would have to rebuild the transmission, everything looked ok when i took it apart but itīs really hard to shift over 7000rpm, no grinding but the gears just take long time to go in. Iīll rebuild the synchros from 1-4 in the next months with new oem parts, i hope it will make a difference.

But i finished my new intake manifold and itīs huge... made a massive difference in my VE map, the old intake lost power from 6000 to 8000 in a almost straight line, now it stays way longer at a higher level, i gained over 10% at 7500rpm.
















Posted by: bloodMoney Aug 24, 2020 - 7:05 AM

Damn. That's awesome.

Posted by: Hafkai Jan 20, 2021 - 6:14 AM

New year, new turbo... wink.gif .. i initially wanted to get rid of the totaly useless internal wastegate of the GTX, it just canīt flow enough to be able to control the turbo, so i was going to replace the T28 exhaust housing with a nice v-band housing but since this is somewhat pricy i decided to spend a little more on a completely different turbo that already comes with a v-band housing and has more potential. I decided to go with a G30-660 AR.61 in combination with a Tial MV-R ... maybe a little overkill on the wastegate side but itīs perfect to reduce boost in lower gears.

Before i swapped the turbo i went to a dyno with the GTX and made a little over 400whp and 350ft/lbs @ about 28psi.

G30-660 vs GTX2867R GenII, the G30 is a really compact unit





Fitting the G30 to the engine was quite easy, i just cut off the T25 flange from the header, put the v-band flange in the same position and everything looked perfect, even the inlet fit without any modification, i just had to rebuild the oil and water lines.



The wastegate on the other hand took some time.... but i found a nice position and iīm really happy how it worked out.







The G30 of course spools a little bit later then the GTX, even with the small 0.61 exhaust housing, but when itīs at about 15-16psi it almost immediately jumps to 26-28psi wich feels really funny wink.gif
The swap was definitely worth the money, at last iīm able to control the boost without crazy overboosts, the car feels way better with this setup. I use a 4port Mac valve for boost control which works amazing, the wastegate is running a 7 psi spring so i have plenty control in first and second gear.

Posted by: Manu_GRMN Feb 27, 2021 - 1:54 PM

a fantastic project smile.gif smile.gif , how did you install the coils on plug ?? what material are needed

Posted by: Manu_GRMN Feb 28, 2021 - 5:50 AM

whaooo good project, you have a diagram to put the bosch p65 coils and what material is needed

Posted by: madk4speed Jun 19, 2022 - 6:02 PM

QUOTE (Hafkai @ Dec 5, 2011 - 3:44 PM) *
I decided to completely remove the old ignition system and build me a coil on plug system. I will use ahttp://i124.photobucket.com/albums/p33/Hafkai/Motor/DSC_2251.jpg as crank angle(24 instead of 4 teeth) and sync pickup. The coils are from Bosch (part#: http://www.bosch-motorsport.de/en-US/literature/en-US/0221504024_DataSheet_enUS_T7730639627.pdf), since they're dumb coils withouh build in igniters i have to use an external (part# http://www.bosch-motorsport.de/en-US/literature/en-US/0227100211_DataSheet_enUS_T6821227531.pdf)
Those coils fit quite well, the only problem could be the hood since they're connectors face in that direction ......


Can you let us know on the P/N of the distributor? I am looking the Toyota parts catalogue online but I cannot find it. Is it a distributor indeed or a Camshaft sensor?

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