Corolla Levin Repair, Paint and Tune - WITH VIDEO

Posted: Tue Nov 27, 2007 11:32 pm Post subject:

Pardal, as always, Worship

Nice work

Posted: Wed Nov 28, 2007 9:47 am Post subject:

Iketani Joined: 27 Dec 2007 Posts: 32

nice project

Joined: 17 Jan 2008 Posts: 1 Location: peru

your car is awesome.....
do you know where can i find body kit pictures??
i'm working on my toyota corolla ae 86, but i want some pictures, so i can have ideas to put together,.,.,.,

I'll be glad if you can help me.

Takumi Joined: 11 Jan 2005 Posts: 411

I guess I can't, because I have not put my mind into it, and I don't tend to. If I had the money, I would have put a CBY kit with some insane offset wheels. But it is just to expensive.

Try googleing ae86 body kit in "pictures"

Best regards

Takumi Joined: 11 Jan 2005 Posts: 411

Well, I havn't had the time to post some news over here, but megasquirt tuning is turning out to be a little more difficult than what I thought it would be.

Anyways, everything is actually working and VE and Spark table are being done. Initially I've had a lot of detonation due to having a spark table from a friend's engine and I realised it would have to be changed...

The spark table is now rising from 20º til 25º @ 5000rpm and fixed past it.

Almost no detonation and the engine is revving fine. It stutters a lot when below 2000 rpm and the cranking and idling is still not good enough.

Can't get it to crank below 10ºC and the battery is getting tired of it.

Had the accel wizard using TPS setting but didn't manage to tune it properly so I changed to MAP which turned to be a lot better. Not perfect... but better.

I think I have to raise the spark table on low throttle so that I can get better response.

Warmup, acceleration enrichments and other aspects still need a lot of tuning, but it runs.

I just need more time to spend around these subjects.

Best regards

Posted: Wed Mar 26, 2008 1:48 am Post subject: A LOT OF RESPECT

Hi Apardal:

congratulations on a fantastic project i have just read the whole lot from page 1 to 17 and have a lot of respect for the work you have done.i am currently doing my own project demo car for my company in Ireland and i can safely say that after seeing your project it has really given me a boost and make me want to go just that little bit further to get it perfect.

Thanks for the inspiration and hope all goes well for you with the rest of the build.

Thumbsup

Takumi Joined: 11 Jan 2005 Posts: 411

Thank you cab32!

Good luck with yours!

Cheerleader

Takumi Joined: 11 Jan 2005 Posts: 411

Went to the dyno yesterday! Trying to figure out what was the power output...

- first test, setup made days before so that I wouldn't hear my home made engine stethoscope pinging... with ignition timing very low.

23º ignition timing above 5000rpm

120.4cv@7800rpm e 117.9Nm@5259rpm

AE86 : Projects > Corolla Levin Repair Paint and Tune WITH VIDEO

AE86 : Projects > Corolla Levin Repair Paint and Tune WITH VIDEO

- second test, tuned the mixture and lowered the ignition timing. Thought it could be detonation holding the power down!

20º ignition timing above 5000rpm

116.0cv@7888rpm e 124Nm@4562rpm

AE86 : Projects > Corolla Levin Repair Paint and Tune WITH VIDEO

At this point we decided we should advance the ignition timing since from the moment it detonates, the engine will loose power

- third test, with data logging always on, another tune was made to the VE map.

26º ignition timing above 5000rpm

135.9cv@7896rpm e 128.7Nm@5123rpm

AE86 : Projects > Corolla Levin Repair Paint and Tune WITH VIDEO

15 hp gain with 3º advance... time to go further

- forth test, removed the air filter

30º ignition timing above 5000rpm

163.4cv@7588rpm e 155.3Nm@7061rpm

AE86 : Projects > Corolla Levin Repair Paint and Tune WITH VIDEO

We were impressed, 7º of ignition advance gave 43hp with a setup that
initially looked like it didn't work.

I could have tried another test with 2 or 3 degrees of advance but I went to the dyno to make just one or two tests and I was already way off my budget!

I think the torque curve is alright, because it's good through 4500rpm until 7000rpm but the value could be a little higher, maybe with a little more ignition advance it will be better. I draw the conclusion that I've no need to have the rev limit at 8700 since my max power output is around 7500rpm.

At the moment, I'm trying to figure out what's the thing with the noises from my home made engine stethoscope because what I thought was detonation, can't be, because it will make strange noises with 23º of ignition timing and with 30 it makes a little more noise, but gains 43hp. If it was detonation, there would be no power gain, I think.

On the road we tried to figure out what detonation would be and raised the ignition timing to 45 degrees and the noise becomes more intensive, for sure, but it is difficult to understand at what point detonation starts.

I'm going to try to drive the car without the stethoscope and raise the ignition advance until I can hear detonation loud and clear and then I'll lower it by 3 or 4 degrees.

Right now I need to decide whether I'm going to install ITB's or not, if I'll change my cams to a more aggressive setup or if I'll leave it be. Either way, I'll need better oil cooling devices...

A video made today driving around the new setup!

http://www.youtube.com/watch?v=xHcqzyXyAIs

Posted: Mon Apr 07, 2008 9:01 am Post subject:

Looks good Apardal! Shows how important a good tune up is Thumbsup

Posted: Mon Apr 07, 2008 10:04 am Post subject:

I really like your video. Nice and healthy sound. Nice driving an nice road Smile

Itsuki Joined: 19 Nov 2007 Posts: 11 Location: Hungary

Itsuki Joined: 07 Feb 2007 Posts: 15 Location: switzerland

hello,
I saw your very nice video,so much power this is very impressive with standard injection system.
Do you still use MS with MAP? obviously you manage to control the ignition(VAST) with the MS?
would you have some photos of the last setup, engine bay etc..
many thanks and congratulations again for your car!
david

Takumi Joined: 11 Jan 2005 Posts: 411

In my engine, besides crank, block and connecting rods, only the intake manifold is stock, but without T-VIS.

The injectors are 300cc's.

I'm using MS with MAP and it controls the ignition, of course.

My engine bay is rather stock... only intake air filter aftermarket... you will find pictures throughout the post!

Thank you for your comments!

Best regards

Takumi Joined: 11 Jan 2005 Posts: 411

ITB's @ Home, YUPPPI!!!!

Very Happy

Posted: Wed Apr 30, 2008 11:58 am Post subject:

Sweet!

Keep going my friend.
When you have it all fitted and running i will ask you to do the same job to my car...

Beijinhos

Itsuki Joined: 07 Feb 2007 Posts: 15 Location: switzerland

really nice, I knew you would go with ITB!
are they the big ones? with T3 manifold, that is going to look and sound really nice!!

all the best.
regards
david

Takumi Joined: 11 Jan 2005 Posts: 411

These are the Silvertop/small ones!

Best regards

Takumi Joined: 11 Jan 2005 Posts: 411

Well, just spend 2 hours updating all the links from my project's photos because they were offline for a few months now.

For all of you who have nothing to do and want to spend dead time... everything is back online!

About the car itself, the news are that I got new TRD 304º Camshafts that run very poorly with the stock intake and the ITB's have not been installed yet because I'm missing the throttle linkage and lever.

I've also installed new oil cooler with new hoses to keep things cool.

To keep dirt away from the engine, I bought a Pipercross PX600 air filter that I'll install as soon as the ITB problem is solved.

Best regards

Posted: Thu Jul 03, 2008 1:21 am Post subject:

Looking great there.. You make Portuguese AE86 owners proud!! Thumbsup

What compression pistons will you be using with 304 cams?
I run about 30 Degrees ignition timing at higher revs (On 100 - 102 RON Japanese fuel) with Tomei cams. With a properly balanced crank, etc. 9,250 is safe, although we've set the rev limiter to 8,900 in the interests of longer engine life.

Have you ported the head, etc. to make the best use of those TRD cams?
These will really benefit from a very high quality 4-1 exhaust manifold too.

Maybe try running the car when it's up in the air and use a plastic tube to try and isolate where the sound / vibration's coming from.... I run 4.778 final too and don't have such problem, although the engine's quite loud, so maybe I just can't hear it, lol...

BTW, your car will get noisier with the mods you're planning. In a good way Smile

Posted: Thu Jul 03, 2008 9:18 am Post subject:

looking good apardal! Cant wait to see a movie of the itbs screaming loud!

Takumi Joined: 11 Jan 2005 Posts: 411

Hi Miguel, I'm already running Wiseco pistons, 0.8mm head gasket and 0.6mm decked head. By my calculations, I have a little above 12:1 compression ratio.

I'm also running 30 degree of ignition timing on unleaded 98 gas, but I really don't know how to compare this grade to 100-102 RON. With this setup, I hear some pinging, but I hope to get it solved with the ITB's, because the free intake helps lowering the air temperature and the engine spends less energy getting air inside.

The head has already been ported (by me) and I hope it is better than stock! You can see pictures of the work done somewhere along my thread.

I've used a cooper piping to hear knocking but either my engine vibrates a lot, or I have detonation even with 23 degrees of ignition timing.

I have one thing I got to work on. It is the camshaft timing. I can't understand why I can't properly measure the max lift angle on the intake side. I install both camshafts as if they where stock cams. The intake camshaft get at 120BTDC and the exhaust at 110ATDC...

Shouldn't they be both at 110 ?

Best regards

Posted: Thu Jul 03, 2008 12:33 pm Post subject:

it may be that your pre-ignition problem is because you have too much compression at the moment. As you increase cam duration to 304 though, the compression ratio will drop as valves will be open for 304 degrees of rotation rather than 288, so this may help improve matters...

Also, be sure to check valve / piston clearance when fitting the new 304 cams. Although it'll probably be OK there's no point in taking chances.

With regard to timing cams, I've only done it a couple of times myself so I don't want to try and teach you! They're different settings for intake & exhaust, not the same. Check say the "Schrick" camshaft website or similar / do a search on google and make sure you understand how to set cams up. I know you realise this is important.

If you're still having problems with pre-ignition once you have the engine running with new cams then perhaps fit a thicker head gasket to reduce compression a tad more.

On mine, I'm running 11.5:1 TPS race pistons, but I don't know if / how much TPS may have skimmed the head, etc. Pre-ignition that can be heard with your home made mic is perhaps fairly heavy - but you can still get pre-ignition that may not be audiable with your kit. Investing in a proper headphone and amplified mic (Det Cans) may be worthwhile..

As a final note it's worth remembering that an increase of compression also means an increase of in cylinder temperatures - which can compound the pre-ignition problems also as well as accelerating wear, etc.

Your project's one of the more interesting ones here - Hope you persevere and get it running perfectly soon - You deserve every success! Thumbsup

Posted: Thu Jul 03, 2008 12:49 pm Post subject: