Nothing pretty build thread

[85GTS]

IIRC the threaded tube I pulled with the cooler from the camry was too long for the 6m block... a spacer will need to be made for me to use the one ive got.

[a2ndopinion]

this is the main reason I decided to try a new style intake, it had nothing to do with the tiny bend which the old style intake has after the TB.  the purpose of these air dams in front of the individual runners intrigues me a bit

Keith, funny you should post that yesterday, as I was noticing the same thing yesterday in the one that I picked up when we were at the J/Y last weekend.

[corax]

Keith, funny you should post that yesterday, as I was noticing the same thing yesterday in the one that I picked up when we were at the J/Y last weekend.

I ended up going to the Vancouver J/Y to scope out another Celica for the lower control arm and picked up the intake.  It's kinda interesting, you have to bore it off-center for the Cressida throttle body - more or less open it up to the bore size just inside the lip at the opening, if that makes sense.

I also want to get rid of the goofy stock linkage with the pushrod when I install this plenum.  The accelerator cable is long enough and the new style plenum has the cable bracket on it, I just need to find a bellcrank to fit the throttle body.  Maybe if I'm really lucky, I'll find an offset bellcrank for a more progressive throttle opening

[corax]

Bob, I still haven't been able to get those struts apart.  It seems they're stuck in the top bearing, I can see a bit of wiggle between the shaft & upper spring perch.  I had them in the compressor at work and my 4 lb sledge did nothing to get the strut shaft out of the top strut bearing.  So I used a bearing splitter to hold the top bearing (part that turns) and popped the whole thing in the hydraulic press, and all that happened was the rubber bushing pulled away from the 3 bolt mounting plate.  I think my next course of action will be to just take a cutting wheel to the shock shaft

[a2ndopinion]

DAMN! Be careful.

[a2ndopinion]

I ended up going to the Vancouver J/Y to scope out another Celica for the lower control arm and picked up the intake.  It's kinda interesting, you have to bore it off-center for the Cressida throttle body - more or less open it up to the bore size just inside the lip at the opening, if that makes sense.

Are you talking like this. I see that it is bigger just beyond the outside lip, and I noticed the TB hole isn't centered.


Oh, and "Light dawns on marble head" (anybody know the movie?)! I kept looking at the angle of the bolts for the throttle linkage, wondering if its angle, Vs the older version being horizontal, would make a difference. Doh! The straight intake changes the angle of the TB by the amount the linkage is angled!

[corax]

Yep.  On mine, I barely had to take the bevel off the passenger side edge of the TB bore but the driver side got taken down to the larger diameter just behind the gasket surface.  I was originally going to keep a small lip in front of the EGR tube to minimize fresh air from cooling the EGR gasses, causing carbon to build-up, but . . . must have forget or didn't care at the time.

[corax]

Oh, and "Light dawns on marble head" (anybody know the movie?)!

thought it was just a NE yankee phrase

[a2ndopinion]

http://www.cswap.com/1988/Cocktail/cap/en/2_Parts/a/00_16

[corax]

this is what I started with today - an old style intake that Toyota used for nearly a decade and an overly complicated throttle linkage with a bunch of slop in it.  I didn't have to change to the linkage to install the upper manifold, but I wanted to.


I put this TB bellcrank, from an early 90's 4 cyl 4runner (22RE) on the throttle body after trimming off the upper cable bellcrank (the crescent behind the pushrod linkage ball).  Note that the ball is the same distance from the center hole as the linkage that's currently on the throttle body - it could be used with the pushrod linkage.  Also, the center hole is already rounded from the factory (not slotted) so it can be rotated on the TB shaft.  This is how it looked originally.

I imagine any late 80s 22RE "cable only/ no pushrod" bellcrank could be used

I was almost able to just use the bracket that came on the new upper intake manifold (no pushrod linkage), but found I ran out of cable adjustment & had to space it back .5" - I cut the upper cable mount (for cruise control) off & welded it into position.   First I adjusted the bellcrank on the TB shaft so the throttle plate is wide open with the pedal completely mashed into the floorboard, then I adjusted the cable so there is just a little bit of slack in it at idle.


The new upper manifold didn't have a nipple for the Aux. Air Valve since Toyota changed over to a throttle body mounted cold idle system when they used this intake. So I bought a .5" O.D. brass nipple and tapped pipe threads into the right spot on the manifold.  The manifold is only about 1/4" thick so careful work with the 1/4" pipe thread tap is in order to prevent it from being loose and becoming a vacuum leak.  There are no thicker areas that I could have tapped, or I would have and just routed a new hose from the nipple to the AAV.  A bit of JB Weld doesn't hurt either.  A screw type hose clamp is necessary to make the original hose seal to the nipple (original nipple is .550" O.D.)


Finished product, everything fits just fine.  The accelerator pedal moves a bit more freely & this project allowed me to Simplify and Add Lightness

[a2ndopinion]

[corax]

I'll just leave this here so I don't lose this info later:

Cressida sedan "big brake" parts:

• caliper + pad saddle = 8lbs
• hub, bearings, grease, seal = 5.5lbs
• stock rotor = 12.5lbs

(no weight taken for R-1 Concept E-Line cross drilled rotors)

Celica OEM parts:

• caliper + pad saddle = 10.1lbs
• hub, bearings, grease, seal = 6.5lbs
• unmodified lower arm + ball joint = 3.8lbs
• strut/spindle, no insert, perch cut off = 9.0lbs

[Sigma Projects]

surprising it cuts 6lbs off the front.

[corax]

If anyone ever wondered, the entire sunroof assembly from an '85 Celica weighs 34.5 lbs. and is 1.75" thick from the roof skin to the bottom of the sunroof pan (including ~1/4" of foam seal thickness) 

And just because I've never seen this one, here's a monkey

[corax]

taking off the 90 degree lip


and the sunroof reinforcement piece is another 2-3 pounds gone


now I just have to trace & cut the piece of solid roof sheet metal 3/8" larger than the opening I just made before using my flange tool on the edges so there's a bit of overlap before welding the filler in.
Flange tool from HF, that will make the filler piece fit perfectly flush