I'm using the engine out of a Mk1 MR2 and reusing the fuel injection and fuel rail.

Question is which end is the supply and which is the return. I am assuing supply goes to the gear box end of the engine.

I have what seems to be two regulators on the rail?

If its not normal, Ill take some photos and post.

yep you will have wat looks like two regulators.

As far as i can remember (my 4age is at home, im at uni) the supply is the larger one with the larger pipe attached (possibly crimped) to it while the smaller return has a smaller pipe clipped to it.

Anyone correct me if im wrong or if you cant see the pipe sizes..

fin

Hey Shades,

Yes perfectly normal, but it's the other way round.
the timingbelt end is supply, the gearbox end thingy is the fuel pressure regulator and the lower tube on that is the fuel return line.
the small tube in the fuel presure regulator is the manifold vacuum line (connects to the manifold on the black vsv)

the extra thingy on the rail is a pullsation damper, it's used for eliminating the pulse that get's into the fuel system when T-vis activates. and the brief moment before the ECU switches to dual firing the injectors on half duration per cycle

before the t-vis is active the ECU sends 1 pulse per injection cylcle which gets pretty long just befor t-vis activates, after that it sends 2 shorter pulses per cycle.

only the earlier systems had this.


here 2 piccies


factory vacuum diagram 4age

and here my old engine you can just see the FPR and the vacuum line on the manifold vsv

Image deleted by owner

good luck!

ps have you still got problems with the cooling system hose layout? I can fill in the ??? in your foto''s if you want?

grtz Thomas

[Edited on 6/5/07 by thomas4age]

[Edited on 6/5/07 by thomas4age]

Thanks guys,

Makes sense, The bigger pipe is the supply and at the front of the engine. The extra hole in the rail I am planning on just blocking off. I am fitting throttle bodies so no longer have the TVIS system fitted. Now I need to find suitable connectors to mate the toyota lines to the 8mm fuel hose :-)

Thomas, Yea, I think i have sorted the cooling (well its all plumbed in now). I have done away with the thermostat... and will wait to see how it runs without.

Adrian

I junked my thermostat but engine now runs too cold so I'm trying to find a suitable alternative as my old Rover SDI 2ltr one dosen't seem to work (and they are now no longer available).

Also, I got my replacement fuel hose / unions from BGC motorsport. Very helpful - I just sent them my old connections & short lengths of pipe and they made up some braided hose & unions which I connected to my solid 8mm fule pipe.

Hope this helps - and let me know if you find a thermostat too.

Rich

Hey Shades,

You'll be fine in the fuel department then,

But do yourself a big favour, PUT THE THERMOSTAT BACK IN!!! the toyota cooling system works the other way round as per a normal system.

leave it out and cook your engine, or have it run so cold (and I mean really cold 40c!!) it will wear out in no time.

there's only one thing the 4age's don't like that's fluids that are not in opperating temp.

Pluming is simple on these engines I only need to make the piccie and repost it here. (since I'm in a very NON active nightshift at the radiostation I'm working at I'll do that right away)

DO please promis to put the thermos back in, you will defenatly ruin the engine whitout one.

grtz Thomas

Right here we go.

remember that teh MR2 has the thermostat lying on top of the gearbox, so if you have the space for the thermostat housing somewher over the bellhousing that would be very comfy for routing the hoses.

if not Ive seen succes install below the intake manifold aswell.

in this pic you can see how the mr2 had it, the left side of the picture faces the 2 tubes coming from the front of the engine, put 2 short pieces of hose inbetween them and they line up very nice
I did not have a heater so I connected the 2 lines to eachother with a T piece from escort CVH (same diameter) and had the coolantbottle outlet on the other side of the T, the brown sensor in the thermostat housing is the cold start injector timer, you won't use that with an aftermarket computer that has cold start enrichment.

MR2 4age thermostat housing

next the engine, the 2 small tubes comming from the waterpump main tube and the bypass tube are normally used to activate a cold start device in the original manifold, since you won't use them you can plug these. the sensor that was in the outlet on the rear of the head (probably a green/beuish one) is the water temp sensor for the ecu.


and last the various in and outs on the exhaust side of the engine. with one neat feature you'll need to get the coolant out of the engine, now that you're going to fit your thermostat :p

Description

can't go wrong

ps if you are using a heater, you can also put the headertank output into the lower rad line,

good luck!

grtz Thomas

[Edited on 9/5/07 by thomas4age]

[Edited on 11/5/07 by thomas4age]

[Edited on 11/5/07 by thomas4age]

Thomas
Do you know what thermostat opening temperature should I be aiming for? I believe it should be 84 to 88 deg C?

Rich

as per every toyota in europe (non scandinavia) it's 82 degrees for the themostat

My engine runs 84c at all times no matter what! exept for once the old 16v went up to 126c whitout problems so 88c should be fine hahaha!

fan on at 94 and of at 88, but a little higher is no problem.

grtz Thomas

[Edited on 11/5/07 by thomas4age]

Oh I now see that one of the pictures in my previous post isn't the right one. So I have updated it.



[Edited on 11/5/07 by thomas4age]