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Discussion Starter #1
Hi volks,

my name is Mike, I'm from Austria (Central Europe).
I just like to post up some pics and texts about my new project
on my IS300 M/T.

Well some story before:
I'm member in the EURO-Lexus Owners Club since 2002 when I bought
a Lexus IS200 powered by the 2.0L I6 VVTi engine (1G-FE),
which I got with a J160 6-speed transmission (also available in the Toyota Altezza).

OK for short.... I started a turbo project on it in 2004 and built it up to the first turbocharged Lexus IS200 in central Europe, there were just 2 or 3 in the world at this time and it came to about 230-250BHP @ 0,65bar of boost
(1bar = 14PSI).
OK in April 2006 I got in a terrible accident on the highway @ ~120kph
and shredded it into pieces.
Well, we started then to rip everything out of it, what could be useful
and put the chassis on the trash.


In 2007 I ordered somebody to import a '03 Lexus IS300 M/T from America in TCM color (which I love very much, since it did never get sold in this color in Europe).
Well.... in October '07 it was time for me to pick it up, put it down to Serbia (where I work for an Austrian construction company) due to tax and law advantages, put it back to Austria ;) and began to start a new Project.
That's why I'm calling it "My Project II" ;)


MY PROJECT II
(this all happened during the Year 2008)

Well, it seemed the IS300 also got involved into a terrible accident
and got rebuilt awfully.
The front is bended to the right side for about 2-3cm, the front and rear skirt
was hanging around somehow. ^ ^

I put it to a Lexus workshop and they solved most of the dents and other
not repaired "issues".
All in all the importer seemed to have cheated me, but I could get it for a good price and I knew that it won't last in stock condition. ;)

OK here, we started to rip out everything and put the whole interior in it,
which we got out of my IS200 Sport.
It had 2 color interior and textil seats (lower weight, not cold in winter)

...was there water inside? :suspiciou











Now it looks like this....




B&M Shortshifter B&M, TRD-GaugePod, Blitz BLM Gauges (Boost, Exh.Tmp., Fuel Press) ;)





Once we rented a garage to do the first steps of tuning....
HKS Hipermax II coilovers, Hotchkis SwayBars & AAC AngelEyes headlights (sorry for cellphone pics)











Angel Eyes.... B)



I also thought on modding the HiFi System a little bit....
Maqma MQ-E04 Tuner


...Subwoofer




To prevent vibrations....






Here we go...


 

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Discussion Starter #2
...the way to go


paint conditioning

handling the whole car with 2000grid wet paper.... :suspiciou





Polishing process crude & fine


2 layers of Meguiars Carnauba Wax and... :)







to come: Clutchmaster FX500 4-paddle & CM Light Flywheel
(cellphone pics)

.....never thought it would be that hard to remove the 5-spd stranny.... :pissed:










never want to miss it, the clutch is not too agressive and very reliable to drive normal, the LFW is awsome.... best way to notice on normal driving style, the throttle response you can feel much better



.....it get's serious
Exhaust System & Piping fitment check...









stuff


not very funny to combine the 2,75" exhaust system with the 3" downpipe...






;)


 

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Discussion Starter #3
....up to fit the return-fuel-system which was once working in my IS200 :rolleyes:





Blitz BLM Gauges und TRD G.Pod install, wiring, connecting....


The new "brain" also needs some place to sit


 

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Discussion Starter #4 (Edited)
Hmm.... nothing is just PnP.... everything is custom-work, since I didn't buy just a bolt-on-turbokit..... everything was choosed seperately, based on
some experiences of the past... ;)

BOV.... couldn't find an adapter flange for the Blitz dual drive BOV....
so I had to create one...


Here we go..... 10mm Aluminium, cut and bore out holes, countersink the boltheads....


seal and fix it....


ready to blow off :)

....for about 2,5h in the forenoon

continuing on the IS200 2,75" exhaust system







Piping works....





Skunk2 universal turbo muffler....



It took some time until it was fitting as I wished.... :rolleyes:
...but it fits right in place (without hooks right now)










at daylight....
 

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wow! i'm speechless, i came in this thread thinking a newbie has a question bout boost, lol wrong!
glad to see your project II is going great so far! i love how you took the TCM and imported it! thats prolly the same color i would've chosen too! one of my favorite colors!
just becareful on the stock w55 tranny, even though you upgraded the clutch, i'm sure you know its the weakest link!
and if you can change one thing, i would change those taillights. yucky!
but great so far! can't wait to see your next update!
 

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Discussion Starter #6 (Edited)
Internals Swap

OK.... we put the Lexus on a trailer and transported it to a workshop
of a friend of mine...
I started to prepare everything.... getting out all fluids (coolant, oil and stuff)
removed wires, covers and and and.....







David vs. Goliath...... I gave up at the cam pulley, couldn't loosen the bolt.... :confused: also not with a 1m wrech...

OK next day I wasn't alone any more.... I had my buddy there and we could
fix it together..... :p

camshafts removed




new camshafts ;)





Well, once a time we could "decapitate" the 2JZ


...nice engine parts collection




everything removed from head


Couldn't believe that on the IS300 the oil pan can't get removed without lifting the engine block :jawDrop:
But we found some "russian solution" :bigSmile:






Now it's down to you and me..... *g*





Carefully with some feeling in the balls we honed the cylinder walls just
slightly.... the orig. cross-grinding was visible but the walls felt pretty glazed



Conrods and Pistons were completely removed, the new rods pistons
(Toyota Supra 86mm, CR 8,5:1) will get assembled and installed.
Head needs to be cleaned and reassambled.

New camshafts, sealings, valve springs, spark plugs will follow
 

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Discussion Starter #7
well.... that took a 12h job without any break....
(this time with Digicam :) )

OK... internals were removed....



What a bloody job to clean and handle the head unit.... :suspiciou clean the cylinder top, valve seats and stuff....




before/after


sealing flange cleaning


well.... sometime.... it looked like this


valve cleaning.... removing burnt oil and other sh!t....


Valve install.... I didn't proof the valve play, but after 50k miles it should be ok ;) just proofed and cleaned the valve seats


Dual Springs


This job has won the first price of all sh!t-jobs in the world....

.... it was easier to remove the oil pan... :confused:

ok, how it looked like in our garage *gg*


oil return




"hmm... and now? WTF! :suspiciou "






get slim and dive...
there you can see the new cross-grinding (little bit reflecting due to flash light of the camera)


....you will....


get the rods to the crank and fix it


sealing the oil pan and mount it
 

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Discussion Starter #8
...continuing work

Replacing head and headbolts (ARP) (80lbs-ft, ~108NM)

(Thanks to America and it's imperial system (ARP head bolt sizing) :suspiciou
Lucky we could use a 13 Gedore nut, made a bit slimmer and could fix everything ;) )

new camshafts fitment


Yeah it was funny how to find out in which position to bolt down the camshafts (watching the piston position) without damaging anything.
We put the pistons somewhere downside and after puting the camshafts in place we took them stepwise to TDC position

Good boy..... for being kind, you get the first bottle of oil immediately :rolleyes:


Everything is in place, also the HKS cam gear


valve cover, belt tensioner and drive belt, also new timing belt came on




Later we also fitted the oil fitting to the oil-pressor-sensor place....
...nice dirty-job :pissed:
 

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Discussion Starter #9
Next steps....


I was alone in the garage, so I did some easier job...
making clear the PHR Denso 440cc Injecors, to find the right fitting sealings
and get them into place...


cut off the stock connectors and soldering the new ones


fit! :)



Finally some boring job was waiting for me.... to mount some covers, sensor connecting, venting connections, electric connectors and other crap....

Refit the manifold, cleaning the piping (inside) and to fit some part of it....

Well, the 2JZ is sitting in the engine bay almost completely


Still waiting for an adapter flange I ordered for connecting the turbo to the downpipe...
 

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Discussion Starter #10 (Edited)
What last week happened....


....yes right.... we got snow :rolleyes:


Well... I have got a 3" outlet to 3" Vband adapter flange


but I needed a 2.5" outlet to 3" Vband flange


...and I didn't receive it for about 2 months... also not yet... :pissed:

So here we go with another custom job.... I have cut it into 2 pieces,
devided just the flange into 4 pieces and reduced them until the 4 holes fit with the holes on the turbo charger and welded them together




On the Vband side I cutted the area where the bolts should sit, bended them inside and welded it together with the flange


It needed to be planned slightly, since it got dented a bit due to welding and bending


Fits, seals and can be used :)
(of course I cleaned out everything inside off the flange)





wiring salad *gg*


connecting sensors as like AEM O2, AEM MAP and AEM boost solenoid to the EMS











The blood-job.... connecting the wastegate to the downpipe




ready for process


cutting out the hole for the wg outlet




It had to be worked really exactly, because it also should get removed and reinstalled after getting hot once ;)




Great, we noticed that we didn't have a flange for the oil return on
the turbo any more. :confused:
The one which should be used is already sitting on the oil pan....

OK, it costed me a 10min job to take it out of the remaining 10mm Aluminium:)


Get some warm clothes..... we have winter time :lol:


Sorry we didn't make any further pics, since we had to hurry....

But we did some Video of the first start up,
not knowing what will happen, after rebuilding the whole engine....
(for the first time in my life ;) )



I just have to say that....
nothing exploded or made any strange noises :rolleyes:


But the engine is stuttering and running pig-fat at AFR 10:1 or sth.
When leaving the foot off the gas it stalled immediately and didn't
idling or anything.


Watch here: IS300 Turbo first start up
(air piping was not connected to the engine, so the turbo was spooling just for fun *g* )

I have to check sensors and setup on the AEM :)
 

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Nice. BUT Why did you take out the leather for cloth seats? (and swap the whole 01 dash in, admittedly it looks better though) THEN Put the stock tail lights on...please for the love of god...put them back on!


Otherwise, hats off to you friend.
 

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VERY VERY NICE. its crazy how far away you guys are. love the wheels, and i hope you make crazy power. nice built. GL
 

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it seems that you really enjoy putting all your time, effort, and some money into rebuilding the engine and car. ++++rep for such diligence.
 

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you definitely went to work rather quickly!

Good job with the hole built, I luv the recirculated dump tube.

Keep us updated!
 

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damn,,now that's a story. + rep.
 

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Wow, I'll give it to you for swapping internals with the block still in the engine bay! That's not a fun task to do with very little working room. Out of curiousity, why not use a T4 flanged turbo? It would have saved you the trouble of using 2 adapters.
 

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Discussion Starter #18 (Edited)
wow! i'm speechless, i came in this thread thinking a newbie has a question bout boost, lol wrong!
glad to see your project II is going great so far! i love how you took the TCM and imported it! thats prolly the same color i would've chosen too! one of my favorite colors!
just becareful on the stock w55 tranny, even though you upgraded the clutch, i'm sure you know its the weakest link!
and if you can change one thing, i would change those taillights. yucky!
but great so far! can't wait to see your next update!
*gg* thanks mate ;)
Well I didn't specially order a TCM model, to be serious, I was just lucky to get one
It was hard enough to find a M/T IS300 model, since the most are A/T and the M/T can just be get in America.

Yes I know about the W55 tranny, I will keep the power down a little bit,
it won't be used as a race car, mostly for official roads and time by time on a drag strip or some drifts. 0,7-1,3bar max.

A V160 swap is planned for 2009 ;)

Nice. BUT Why did you take out the leather for cloth seats? (and swap the whole 01 dash in, admittedly it looks better though) THEN Put the stock tail lights on...please for the love of god...put them back on!

Otherwise, hats off to you friend.
I don't know if the Sport-Interior ever was available in USA,
but I love it! U got it in 2 color (dark gold and black), alu-pedals and stuff.

Further the condition of the bone stock imported IS300 was terribly bad,
the dashboard was scratched, the carpet was marked with puke-spots, rust,
hairs from some idiot dog, sand from Florida Beach mixed with some reed :confused: , Dollar Coins and other crap.
Don't have an idea what relly happened with that car, maybe it didn't get put on a container ship, rather it was swimming over the Atlantik by itself started in Florida. *haha*

The leather seats were not bad, but I didn't like the grey color first
and second leather seats are much heavier (heating & electric) than the cloth seats (performance ;) ), third they're pretty cold for the first time in winter.

VERY VERY NICE. its crazy how far away you guys are. love the wheels, and i hope you make crazy power. nice built. GL
THX mate :) the wheels I bought in 2003 for my IS200, they are from TTE (Toyota Team Europe) something like TRD.... called "TTE GT-One" in anthrazit color, but it's shining in perl effect between a little bit violet to anthrazit and dark grey.
They are 18" rims with 225-245 possible rubbers.
Damn expensive stuff (500EUR per piece just the rim) made by Speedline, I bought one additional, since I crushed one in my accident in 2006.


it seems that you really enjoy putting all your time, effort, and some money into rebuilding the engine and car. ++++rep for such diligence.
Well... I wouldn't say to have much time for my ride, due to my job, I'm at home just for about 6 days/month (2 weekends).

great work, and excellent pics.....good project.

my suggestions: lose the cheap tails, tint the fogs, and get rid of the orange sidemarkers.

not a big fan of the seats, but they go with the car alright. Lovin the dash though.
Hmm... wondering that in America people really don't like the taillights and fog lights. :confused:
Do you have an idea how hard it was to get those fogs? *ggg* :rolleyes:

In my opinion dark rear lights are a MUST on a TCM IS300. ;)
Here people like them pretty much.
I really wanted dark lights for my car, at all the stock tails were not same colored, one was shining in some blue tone and one was completely chrome
also the red fogs I didn't want next to the TCM color.

Wow, I'll give it to you for swapping internals with the block still in the engine bay! That's not a fun task to do with very little working room. Out of curiousity, why not use a T4 flanged turbo? It would have saved you the trouble of using 2 adapters.
Haha, you're right..... working on the engine mounted in the engine bay was not funny. Problem was that we didn't have an engine crane, since it's a garage from some chip tuner who is just doing service and some chip-tuning on Europeans loved TDI (Turbo Diesel Inj.) cars, not a kind of some serious performance tuner.
Performance tuning this like is not as common as in USA, it's hard to find any good tuner or to get tuning stuff.

As for turbocharger.... I have choosen a turbo for the allround-performance.
Quick spool-up and although quite good endpower was an issue for me.
Quick response and efficiency was the most important reason.

So I was going with a Turbonetics GT-K500 and it was just available in T3 setup.

Yes I welded a T4/T3 adapter on the manifold, cutted the T3 hole in a V-shape
(T4 hole running merging v-shaped to the T3 hole) so it's giving the exhaust stream
an additional nozzle force for a slightly quicker spool up. ;)

So I was aiming to kick a 1000BHP ride's a$$ during 1-2nd gear while he is waiting
for passing turbo-lag. *gg* ...since it's also important for drifting or some curcuit racing
to have full-thrust over nearly the whole rpm-band.

On my IS200 turbo I could make it to get spool-up at 2500rpm and pulling as sh!t until 6500rpm, that is pretty useful for launching and when taking other slower cars, you don't need to shift down 1-2 gears always.
Further it's also some advantage for the high-fuel-price-days to save some Euros on fuel. *g*

And I'm not using it on drag strip very often, I want it also as a daily driver ride
it doesn't make an effect if I get 500 or 1000BHP.... I wanted that the Power matches to the car and the car to the Power. ;)




So far all the tuning stuff I ordered in America, after all the troubles with toll-office and shipping services, so i have to say
THANK YOU VERY MUCH FOR ALL SUPPORT AND HELP TO:
Joe @ PowerHouseRacing
&
Justin/Jon @ JSC-Speed
 

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Glad to see the car come together, looks nice!! Something else you need to do is get our fuel Rail and make a fuel System with our Dual Fuel Pump Bracket. :)

I have a new Radiator Show Plate coming out soon.

Thanks,
Joe
 

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Wow nice work i deff have no patience for doing that kinna work lol. how much hp you expect to make?
 
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