My Lexus Isupra Conversion

[gsportcars]

Hey there

Great conversion.

I have a 1JZGTE VVTi with Getrag V160 fitted into my IS200. I see that you have found most of the small changes that you need to make - almost the same as mine. (For the tailshaft I use Landcruiser front shafts - everything in my car is Toyota sourced)

Things like the sump mod, greabox linkage shortening etc etc. - there is a never ending list of minor items that consume the time. Other items yet to be mentioned include air-conditioning connection, power steering connections as well as the best part - making 2 ECU's talk intelligently to each other. I have an Autronic SM2 fitted together with the IS200 ECU in the same case sharing signals. Took some working out.

Wait till you have to get the climate control to work - can help you with those sorts of issues.

Keep up the great work.

Cheers

Graham D

I think I have the ecu problem sorted. I already have the SM4 installed in the car so it is a simple swap over the supra engine. I have had the Autronic fitter/mapper down already to look at the car and have already sorted the wiring loom out. Not expecting it to just simply work but hopefully shouldn't be too difficult.

The power steering pump connections are the same and I am doing without the aircon for the time being. I know what needs done to run the air con but I am not installing it yet.

Cheers for the comments so far anyway guys. I will have some more pics up soon!

[P4UL T]

Well done fella, this looks great.

I also take my hat off to you

[Mr Morse]

You're doing an awesome job there Gav, keep up the excellent work!

[gsportcars]

Sorry guys edited as the pics were hooooge

Will get them resized and re-posted asap.

The power steering pump is on the passenger side of the 2JZ engine unlike the 1G where it is on the driver side. For this reason the standard IS200 powersteering hose is not long enough to stretch from the steering rack to the pump. Luckily enough the supra one is longer and has the same fitments on each end. After a bit of bending and twisting etc etc i managed to make the supra one fit.

Here is the standard IS PS hose. It is covered in reflective heat mat as it was very close to the old turbo when fitted

This is the supra hose fitted to the steering rack but as you will notice it exits towards the rear instead of coming forward.

This pic shows the new routing of the new PS hose. It goes under the cross member and will come up to fit on the pump when the engine is in.

The PS system also has a return hose that goes from the steering rack back to the PS resovior. This also had to be modified as the resovior had to be moved to the passenger side of the car in order to feed the PS pump. Here you will see the routing of the return hose as standard. It comes across the front of the radiator then "U-turns" and goes back into the driver side.

I have now straightened the hose so it goes all the way across to the passenger side without the U-bend.

This way it still gets the benefit of the aircooling.

Youw will see in this pic that where the return hose used to be clamped in the double clamping bracket

This is the end of the return hose to which the rubber pipe gets connected to and then to the resovior

Once the car gets going it will be important to have good stopping power so when Mat was selling his LS400/supra big brake conversion I decided to snap it up. It uses the Lexus LS400 four pot calipers with a pair of UK spec supra discs. As soon as I had taken delivery I got to fitting the new stoppers.

Here is a comparison pic of the old brakes vs new brakes. the only modding i had to do to get them to fit is to trim a small section of the cooling plate that sits behind the discs as the caliper slightly fouls it.

I will post some more pics of them fitted soon.

I have also re-located the powersteering resovior among some other things but have not yet taken pics of them so they will follow.

next on the shoppping list is a new clutch so I can then get the engine fitted in for the last time and I am still waiting on my custom prop shaft which should be ready anyday now.

Oh.. and the oil lines for the turbo are also being made at the minute too.

:D

[Mr Singh]

Looks excellent.

Suggestion on the PS piping etc.... how about you install a small cooler kit, just like you would use on an engine oil cooler. A small mocal 7 or 10 row 115mm width cooler with some push on hose will be more efficent than the stock bendy pipe arrangement.

[Bazza]

dont know about everyone else

but... i am really enjoying this thread

cant wait for the next installment :D

well done gav :)

[peter026]

I have nothing but admiration for people who take on these tasks, and love to keep up with what's going on.

Probably because I'm a bit of a Numpty with most things mechanical.

Glad you re-sized the pics, as I was going to go out this weekend and get a wide screen monitor :D

[marcus]

Keep up the good work gav, .............i will be going down this road soon :winky: so you could have alot of PM,s comeing your way :D

[gsportcars]

Looks excellent.

Suggestion on the PS piping etc.... how about you install a small cooler kit, just like you would use on an engine oil cooler. A small mocal 7 or 10 row 115mm width cooler with some push on hose will be more efficent than the stock bendy pipe arrangement.

I will prob be doing something like that in the near future but for the minute I wanna get it in and running with the very little funds I have :duh:

Keep up the good work gav, .............i will be going down this road soon :winky: so you could have alot of PM,s comeing your way :D

No probs mate glad to help if I can.

Thanks again for all the comments guys!!

[gsportcars]

I still did not get any pics of the new gearbox so here are a few.

First the V160 beside the J160. You will notice how bulkier the V160 is compared to the old box. It also has cooling fins on the bottom which you don't see that the old box doesn't have. I have heard that this gearbopx can get very hot indeed.

couple more pics

I decided to take a few comparison pics of the old and new turbos. You will notice that the new turbo has a much larger exhaust housing but only a slightly larger compressor housing. I am no turbo wizard but I am assured this turbo will run 500bhp when mapped correctly. Plenty for me at the minute :P

I decided to remove the old supra wiring loom from the engine as it is not needed anymore. This is partly due the fact that I am running the Autronic ECU and only a handful of the original sensors are needed and partly due to the fact that my standard IS loom has pretty much all the same connections as the supra one.

This is the engine with the loom still in place....very messy

The loom is half off the engine

This shows the pressure tank under the inlet manifold but it is now also removed.

The supra loom completey removed from the engine

I also recieved my fuel rail and injectors back from the states. When it was first sent the injectors did not fit in the rail. i sent it back and the guys in the states sorted it for me before returning the package. The injectors are Delphi 960cc and the fuel rail is a custom made one designed for the 2JZ-GTE engine. It now fits perfectly.

Here is the rail and injectors fitted to the inlet manifold.

I have test fitted all the parts of the engine and gearbox that have been modified to fit. Things like the sump, gearshifter location bracket, gearshifter rod, gearbox cross member, custom prop shaft, power steering resovior and hoses, manifold and turbo etc etc etc. I am very pleased to say that everything fits perfectly and as it should.

This is a huge relief for me as in the time I have been waiting on parts coming back to me before I can test fit them I have constantly been wondering ..... "what if I measured that wrong?"......."what if I forgot about that?"......."what if I didn't explain that right to the engineer?" etc etc etc. Gladly everything fits so far and my mind is slightly more at ease now

I now have to wait on my new clutch arriving and have to get my flywheel faced also. I can then bolt everything in for the last time :D :D . After that I will be custom making my own exhaust and intercooler piping and then it is mapping time!!!!!!!!

I will keep you guys posted with more pics as they come.

[aido]

You've got some serious skills mate :D

Can't wait until this is up and running, it's like the Monster thread all over again :)

What's the ETA on the new stuff arriving and then you sorting the custom pipework?

Now that Mat is detuning his white car for drifting purposes it looks like you're going to have the most powerful IS on here fella, it really is awesome!

At this rate Steve will be trying to buy the car back when it's all finished :P

[Ellz]

Looks very nice indeed that fuel rail look the EFFFING nuts mate

[marcus]

nice one gav, :D i for one can not wait to see this up and running............ :winky: keep up the good work mate

[gsportcars]

Aido should be a few weeks before it is al sorted. There are still some very minor bits which need doing etc but it is just getting the time to do it. The missus has got an induction date of Sunday 22nd Oct for the new baby to be induced so I am trying to get as much done before then LOL.

[derekyau]

The next challenge would be to do this over a JAE weekend! lol

Looks like a fair bit of time and money invested in this project.

Good luck with it still.

D.

[aido]

Aido should be a few weeks before it is al sorted. There are still some very minor bits which need doing etc but it is just getting the time to do it. The missus has got an induction date of Sunday 22nd Oct for the new baby to be induced so I am trying to get as much done before then LOL.

PMSL :D

Is this your first kid then mate?

All the best on that one, just looked at the date and it's only a few days away!

[gsportcars]

Yeah it's the first one...can't flippin wait though. just wish it was here already :D

It's amazing what you can get done in a few days.

[Noel]

Yeah it's the first one...can't flippin wait though. just wish it was here already :D

It's amazing what you can get done in a few days.

My 3rd kid was born on monday, 9lb baby boy.... :)

[gsportcars]

Congrats matey!!!!

[aido]

Congrats Noel, I think they must be giving you Irish boys some Viagra when you're importing your cars as your partners are all dropping sprogs lately!

Well all except for GRiM as we know he bats for the other team :P

[elexes]

Congrats Noel, I think they must be giving you Irish boys some Viagra when you're importing your cars as your partners are all dropping sprogs lately!

dont say that i cant afford another and my mods at the same time

congrats on the baby

[gsportcars]

Hi people,

I have not had the time in the last few weeks to make too much progress with car as I have been busy with another addition to the house.

here is the latest modification made to my life :D

Yeah I know I have a BMW t-shirt on but it was a freebee and is only used to wipe my oily hands on.....honest

His name is Jay

I have got some work done to the car though :P

Here is my old clutch that I recieved with the gearbox and also the standard flywheel. The flywheel is in rough condition and needed faced.

Here is the flywheel after i got it faced and it is fitted to the engine.

This is the new clutch that I recieved. It is a centreforce dual friction clutch. from what i have been told it will handle around 600-700BHP and still retain a factory feel. I would have used a paddle clutch but I don't think little Jay would have appreciated the jerkiness of the on off type clutch

Here is the clutch fitted. Note that this clutch uses the same genuine Toyota outer housing for proper fit.

I have also been getting my oil lines for the turbo made up. This is the braided oil return line.

I have now got all the oil lines but will get pics fo the rest soon.

i took a trip to a local breakers yard to source some small parts like clutch slave cylinder etc etc. i ended up finding an aluminium top rad pipe and some pieces of intercooler piping from what I think was a Greddy hard pipe kit. The pipse are very dirty and corroded looking so i have since sand blasted them among other parts and they have come up brilliantly. Once again I still need to get some pics.

I have also fitted a new timing belt and had to find a shorter fan belt to use as I have removed the aircon pump from the car. for anybody interested in this the new fan belt is now 1863mm long and fits perfectly.

After not finding a clutch slave cylinder in the breakers yard I just bought a new on from Toyota at a cost of around £50-£60. I have painted my rocker covers temporarily as i will be getting them airbrushed some time in the future.

I will keep you guys posted with more as it comes!!!!

[lee_iceman]

Congrats on the little one

Welcome to LOC baby Jay

You are teaching him well, showing the finger to BMW :)

[gsportcars]

He did that himself. i just seen it and grabbed the phone to take the pic!!!!!

[peter026]

Congrats on your new addition..........Mother and Jay doing fine I hope :winky: