SM105K's SHO BIBLE/BUILDS/LIFE

[SM105K]

Lexus update: I am gong to break this down over a couple of posts. One post will be about what happened and the diagnosis. One post will be all about the parts and why I chose them. One post will be about installation, and one post will be about tuning. I took the Lexus apart roughly a month ago. I was driving it normal and it started missing and smoking really bad. I got home and starting looking at what happened. It would start it, it would immediately start missing, smoke, and smell like fuel. I immediately thought SPARK.

I pulled the intake off and pulled the coils and wires. I inspected the wires and they seemed fine. I pulled the plugs and they seemed okay just one had some fuel on it. I swapped out the newer coils I bought for the old factory ones, and put it back together. Started it, and no change. I thought to myself, did the Haltech Triple Channel Ignitor go out again? So I ordered another one. Waited a couple of days and when it arrived I installed it. Went to start it, and zero change. However, I am happy I have an extra one now.

However, when I let it run this last time I noticed a very strong fuel smell from the exhaust of the engine. Being a inline six cylinder, in my mind it has a hot side and cold side. There are zero fuel lines on the hot side to leak so where is it coming from? I loosened the downpipe. Started it up, and sure enough fuel was spraying out of the turbo. I found my problem. It was a stuck injector.

The Lexus had a set of old school Precision Turbo 880 cc injectors. They were installed in 2008. Remember this car sat for a better part of 5 years and I did change the fuel from 91 octane to E30. I don't know if that was a contributor to the malfunction, but it is what it is. So knowing that, I started ordering the parts that you see pictures of above.

 

[SM105K]

Lexus Update: So I had been kicking around the idea of putting an upgraded fuel system in the car. On the Lexus 2002 Lexus IS300 the fuel system is returnless. When SRT build the car in 2008 they upgraded the injectors and they put a Walbro 255 pump in tank. They retained the stock fuel line, stock fuel regulator, and stock fuel rail. On 91 octane and 17 psi the car made 440 hp and 414 lbs of tq.

When @stripSHO stepped in to help me tune it we wanted to make some changes. We changed the fuel over to E30 and immediately noticed a difference in performance. We were able to turn up the boost to around 20 psi. I would venture to say the car was making over 500 hp. On the 255 pump the car was doing work, however we both agreed that was the ceiling and it was beginning to run out of fuel. I purchased a 350 lph Walbro and installed it. Even with the bigger pump, the writing was on the wall. I would need a boost reference fuel pressure regulator, and a return type fuel system. Since I had an injector failure, new injectors were needed.

I started my research and landed on a Radium kit. Included in the kit was a fuel rail, fuel line adaptor kit, a fuel rail dampner, a boost reference fuel pressure regulator, and all the lines and fittings (minus the -6 an fittings I would use to run the fuel line). I went Radium because it was a complete kit and would work with the stock style injectors I was planning on purchasing.

I had to go to my local speed shop and piece together the -6 an fittings and fuel line to attach the fuel rail to the fuel pressure regulator, and from the regulator to the fuel hat in the rear of the car. I had to purchase a bulkhead fitting and drill it into the hat to retrofit the return line. These guys do a pretty good job of explaining how to retrofit the system and why it is important to do it correctly. Around the 17:45 mark they show how they did it. I used a pop rivet to block the stock regulator instead of epoxy after watching an update from them.

For fuel injectors I went with DW 1000 cc injectors. These will allow me to run more fuel, more boost, and make the power level I think we can hit with this step up. DW said they were direct replacements for a stock Lexus IS300 and they were right. However, the connectors were not, so I had to address them.

I also purchased a fuel pressure gauge that matched my boost gauge. It is nice to have as much information as possible I believe. Plus these gauges throw alarms, they have recalls, and they match the amber color dash in the car. All wins in my book.

 

[SM105K]

Lexus Update: I started the tear down. Here is a picture of the engine buttoned up.


I removed the charge pipe, throttle body assembly, middle piece of the intake, and then the second piece of the intake. There is actually three pieces to a 2JZ-GE intake. Yes three pieces, they are hideous looking however, they do work pretty good. After the last piece was taken off, I removed the stock fuel rail, injectors, fuel line, and all other vaccum and coolant lines.


All the parts on the table mapping out how I will run the lines and fittings.


DW 1000's.


Fuel Injectors and Fuel Rail Installed.


I started re-stalliing the fuel rail and injectors. During this time I changed the spark plugs and reinstalled the coils and wires. Everything went pretty smooth until I had to start soldering connectors for the new injectors. I have an older soldering iron that was not up to the task. So I purchased a new soldering gun and it went very smoothly. Having the right equipment is half the battle.

Helping hands doing their job for the soldering job. These are a must have if you solder. Trust me.


Installed the new fuel pressue regulator with all fittings where the Haltech Triple Channel Ignitor used to live. I relocated the ignitor towards the front of the engine bay and way from the heat.


Made sure the hood shut with the pressue regulator mounted. It did.


Next I worked on the fuel hat. I drilled and tapped it and installed the bulkhead fitting. I would replace the original one that I bought with a different one later. It was just a better piece with better washers. I also was having issues with the line that attached to the bulkhead fitting to the jet pump. It kept kinking, cutting off return flow and was making the bulkhead fitting leak on top. I have since changed that line and it works like it is suppose too, however it isn't ethanol compatible and started getting greasy lol. I have a ethanol compatible corrugated line being delivered today, to that will fix that problem.

Picture of the bulkhead fitting installed in the fuel hat.



Picture of the stock regular blocked with the pop rivet.



I put the fuel hat/pump assembly back together and reinstalled in the tank. I would take this out roughly seven to eight more times fix the issues that I was running into too. Good news is, I can get the pump out of the car in under 5 mins. I ran the fuel lines and secured them.


Then I changed oil. The oil was pretty clean, but it was saturated with fuel. New Valvoline VR1 goes back in with a K&N filter.


Put the intake back together and went to prime the system to check for leaks. The Lexus was dead. Pulled in the Focus (because it was the only car that fit) in and jumped the Lexus. No major leaks expect for the bulkhead fitting which is fixed now.


Installed the fuel pressure gauge in the car.



Car fired right up with the revision that stripsho sent. However, it would only run for a couple of seconds before it died. However, those couple of seconds were enough for me to realize she was running on all six cylinders. A revision was sent and boom she idles. No leaks and a smooth idle was music to my ears. Remember, the tune has to be completely re-worked with the new fuel system and bigger injectors.

All in all not a bad install. It was just time consuming and moderately expensive. Roughly $1500 for everything.

 

[FrankK]

Good work SM! Are you still working on the CyrO2 Intercooler Kit?
StripSho really understands what he is doing.

 

[SHOthyme]

@stripSHO I called it, that's awesome, ha!

Glad to hear it is up and running for you!

 

[SM105K]

Good work SM! Are you still working on the CyrO2 Intercooler Kit?
StripSho really understands what he is doing.

Frank,

On page 55 was the install of the the Cry02 kit. I used two spray bars, however when I installed the 20 lb bottle it just created too much pressure that the solenoid wouldn't open. So I still need to get the 10 lb bottle filled and start working on that. Hopefully I can get the some type of results with it cooling the intercooler.

Yeah the dude is pretty smart. He has really taught me a thing or two.

 

[SM105K]

Lexus Update: Tuning. With rebuilding the tune, @stripSHO has been top notch. He reached out and asked if I would let him tune the Lexus. The Haltech system in the car is old and there aren't very many tuners willing to tune it. Even the guy that tuned it, said upgrade and he would think about tuning it. Most want me to upgrade the tuning computer, but it isnt feasible right now.

He has worked numerous hours on the initial tune reviewing it, giving options, and then executing changes we agree on. Each step I have been comfortable with as we continue to go in the right direction for my goals with the car.

This new e54 tune has been fun. I am learning as well. I am by no means am trying to learn how to tune, but I am picking up on things and starting to understand what changes effect what. We have even gotten to the point of remote access to my laptop and tuning on the fly. That is been very interesting to say the least, and not in a bad way.

He is still working on the tune. It idles and drives which is good for getting data that we need. I plan on turning it up until we run out of fuel on this fuel pump. Hopefully it will get us to the 600 hp range. I will update this thread as the tune progresses.

 

[SM105K]

@stripSHO has been plugging away with the tune. Car idles and drives great. We are slowly starting to turn up the boost now. It is interesting how different just a change in fuel has been. I know there will be more variables with the final tune.

However just some observations between the tunes now. On 91 octane the car felt more laggy in the mid range and the power band was super peaky. On E the mid range is better and the power band seems to be more linear.

It will be interesting to see how different the power band and output will be once the tune is final.

 

[SM105K]

Lexus Update: @stripSHO continues to deliver on the tune. Over the past couple of weeks, we have turned the car up from 10 psi up to 26 psi. He has kept the timing conservative because the stand alone Haltech does not have knock sensing capabilities. I have been listening for knock and pinging but I havent heard anything. Remember we are on e54 so we should have some more resistance.

However, why should we cut ourselves off at the knees? I purchased Tuner Nerd Knock Monitor Pro V3. It should be here on Friday and I want to install it this weekend. Once that is installed I will be able to monitor knock. That will give us a clear idea of how more she will have in her.

Also, I have another another DIY Ice Water Sprayer I will install in conjunction with the Co2 sprayer.

 

[SM105K]

I was planning on installing the Tuner Nerd Knock Pro V3 this weekend because it was suppose to arrive on Friday. However, DHL is the worst shipping company, hopefully it arrives today. It was shipped from Jamaica to Cincinnati, to Miami, back to Cincinnati, and then got a hold placed on it all weekend. Yesterday they shipped here to PHX. I don't know the ass backward fuckery of DHL...but yeah.

I need to fix a small leak on the turbo oil return line as well. I did adjust the clutch again, and I modified the short shifter itself. Took a map gas torch, but I got it handled. Wish I would have taken before and after pics. Car is running damn good. Can't wait to see what the Tuner Nerd says, because I have a feeling we can turn it up even more.

 

[FrankK]

Thanks SM,

Always look forward to your posts.

BTW what is your name?

Frank

 

[SM105K]

Thanks SM,

Always look forward to your posts.

BTW what is your name?

Frank

Hahah, I have competed in the sport of strongman for the past 13 years. SM is Strong Man, 105k is 105 kilos or 231 lbs. I complete in the under 105k/231 lbs class.

 

[FrankK]

Hahah, I have competed in the sport of strongman for the past 13 years. SM is Strong Man, 105k is 105 kilos or 231 lbs. I complete in the under 105k/231 lbs class.

And the mystery continues.

 

[SM105K]

And the mystery continues.

Chef, Executive Protection, Fugitive Recovery, Strongman, and all around a swell fellow. Pretty much sums it up.

 

[bpd1151]

Chef, Executive Protection, Fugitive Recovery, Strongman, and all around a sexy swell fellow. Pretty much sums it up.

**** Fixed ****

Sent from my SM-N986U1 using Tapatalk

 

[SM105K]

**** Fixed ****

Sent from my SM-N986U1 using Tapatalk

Sweet talker.........

Lol.

 

[FrankK]

Chef, Executive Protection, Fugitive Recovery, Strongman, and all around a swell fellow. Pretty much sums it up.

Good reply SM!

 

[SM105K]

Okay, so the Tuner Nerd Knock Pro showed up last night. Looks like a pretty easy and straight forward install. Going to try and get it all installed and have some data by the end of the weekend.

List so far:
Fix oil leak on turbo return line.
Install and log knock pro.
Install DIY IC water sprayer.
Fill 10 lb co2 bottle.

 

[SM105K]

Thanks SM,

Always look forward to your posts.

BTW what is your name?

Frank

Frank, I just re-read your comment. My actual name is Easton.

 

[luigisho]

Chef, Executive Protection, Fugitive Recovery, Strongman, and all around a swell fellow. Pretty much sums it up.

I ran across this the other day. Reminded me of the memes a while back