Lexus is300d Compound swap.
Lexus is300d Compound swap.
Finished the New 3" Exhaust, all stainless steel tig welded i used a V-band to connect my new downpipe to the exhaust. Because this downpipe will be replaced soon for the new turbo.
![[Image: IMAG1388.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMAG1388.jpg.html)
Absolutely love the noise of it now, Just have one backbox in place.
Made a lower Coolant line to clear the alternator.
![[Image: IMAG1403.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMAG1403.jpg.html)
Got my hands on a new starter solenoid and brushes after the old solenoid decided it would be okay to stay locked on, Thankfully battery was low and it didnt start but none the less didnt want to take chances
![[Image: IMAG1392.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMAG1392.jpg.html)
![[Image: IMAG1393.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMAG1393.jpg.html)
Got a new alternator to compliment the start and put the 16 year old engine electrics to bed
![[Image: IMAG1394.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMAG1394.jpg.html)
Well this will have to be removed shortly
![[Image: IMAG1404.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMAG1404.jpg.html)
Along with this little nozzle restrictor that i removed while i gave it it's first full tank of diesel
![[Image: IMAG1405.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMAG1405.jpg.html)
![[Image: IMG-20150228-WA0002.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMG-20150228-WA0002.jpg.html)
Got a few odd looks while removing the nozzle restrictor and im sure ill get a few more when i fill it up in future
Changed the wheel to a genuine Nardi Deep corn ive been dying to fit in the car and also fitted the new paddle shifters while i was at it.
These still need to be wired in but that will happen shortly
![[Image: IMAG1406.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMAG1406.jpg.html)
Day time shot as is, im not happy with the bumper as i cut the hell out of it to fit the cooler and clear everything, I think next up ill fit a stock cooler and heat the lower pieces with a hot air gun and shape the bumper to clear the intercooler end hoses.
![[Image: IMG-20150228-WA0000.jpg]](http://s1235.photobucket.com/user/seanyt2/media/Is300d/IMG-20150228-WA0000.jpg.html)
Car is in limp mode as it stands but my engine tuner emailed me a "New" map that has all the smoke/torque limiters raised and also the limp mode fuel tables replaced with new ones and a little more.
Car runs well but only creates boost after 4k when the stock wastegate cant flow anymore.
So tonight i wired the turbo up to my arduino 722.6 controller and set it to 1bar for 0-100% throttle and the car flys.
Still have the tacho / rev / coolant and few other lights to wire up on the cluster but so far so good.
Tacho is easy just 1 wire from the abs, for revs i will need to build a vr amp circuit but also not a big job. Rest is just wiring direct to the clocks
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Been holding off on this post for a while,
But finally making progress. Not due to there being so much work, but back to me me having time.
To begin a chose an is200 for this engine not the other way around. i did consider Nissan skylines and silvias etc.
Only because i didnt want to have to swap the sump or modify them.
I also didnt want to have to modify the subframe. My plan was to bolt the engine in with as little welding or custom fabrication as possibly.
Im not worried about custom oil lines, coolers plumbing etc.
I bought an e300td crashed and stripped what i needed from it.
Then got a lexus is200 drove it for 6 months then sold the engine, gearbox, ecu for what the e300td cost.
I sat the om606 on to a spare is200 subframe and realised that everything cleared perfect. Not only this but it sat on its own mounts in the perfect position.
Any further back and it would foul the firewall and further forward and i would have no radiator space. it also lined closely up to two holes in the subframe. So i got two stepped spacers made up and bolted the engine in place.
Needed to get 60mm brackets made to lower the anti-roll bar. But it is still above the subframe and acts as great protected for the front of the om606 sump.
Decided to use the stock gearbox mount and plate. and made two brackets for the plate. These alloy brackets bolt to the lexus body and the plate bolts to these. Easy so far.
Sent the prop off to get redone for the 722.6 gearbox.
Removed the viscous fan, fuel filter housing, fitted a new waterpump, serviced the engine. ran a new fuel return line through a vapour line on the is200 as it runs a returnless fuel system. mounted an x5 filter inline also.
Then got a bracket made that bolts to the EDC pump and allows a banjo fitting to bolt on.
Bolted on two oil coolers one engine the other gearbox, Got some lines made up for these. originally planned on a oil thermostat inline but was advice the om606 already has this, making that job easier. Fitted a return line from ps pump to rack and got a high pressure line made for power steering
The coolant lines are all custom but nothing fancy just 16mm alloy tube and some 90 bends.
The radiator line are a little harder. lower line is a reducer and a stainless piece a made to clear the alternator. The upper line for now is a basic join but very tight so this will be changed when i get an alloy radiator and relocate the upper hose outlet.
Inter cooler was supposed to be a 600x300x75 nice big one but the height was far too high for a lexus bumper leaving 30-40mm sticking out the bottom. So i then fitted a 550x240 instead fits nice although today the bumper got a serious shave to let the air in.
The stock ecu was socketed and a cr1 immo chip was fitted and one chip reprogrammed, so it started first turn every time now.
The original is200 throttle cable was fitted to the e300 tps sensor with minor work.
The ecu and glow plug relay both fitted into the is200 ecu box with some trimming inside but not obvious outside.
The vacuum pump is now plumbed inline with the brake servo for assisted brakes.
The bonnet was notched slighly on the drive side to clear the front of the cylinder head.
Still need to make an exhaust for it but have 3" and 80mm stainless for that.
Ole jefer 722.6 gearbox controller is fitted and tapped into the tps sensor.
The e300 shifter was cut down alot. and bolted to the original shifter bracket then fitted in place.
The shifter shaft was shorted and rewelded, then after i fitted the controller i set the length so each PRND was in the correct slot.
The stock turbo is fitted but the wastegate vacuum is not connected.
Also the egr is blocked at the exhaust and the original egr valve has been replaced with a 2" alloy inlet.
The maf and egr are removed so i presume the car is gone into limp and wont boost either way.
The is200 fans are run off a radiator switch so 2 12" fan where mounted to the front of the rad and wired in.
the overall goal is 400-450hp with a broad power range,
To achieve this is have an 8mm Dieselmeken EDC pump good for 170cc
a he351ve turbo with a can controller i built.
I also have now a 50trim t3 turbo and two wastegates. supposed to be a 60mm but allows 2" pipe and is measured at 44mm internally.
Still need to get a manifold made but got the flanges i need laser cut.
the ecu will be remapped by a friend.
Im not expecting the stock gearbox to last long, so i have an e55 amg gearbox with blown oil pump, and a 270cdi gearbox.
Im hoping to make one good box from the two they both cost the sum of €50 so there definitely worth a rebuild.
The is200 rear diff is stock and not known to handle abuse or power. so im looking into different options is220d / is250 / is300 and also isf options are being looked at.
Ill get all my pics uploaded soon and post them up, i know no good project is worth anything without them.
But today i got to drive the car be it just under low speed with no turbo spooling but a good start.
The poor front shocks have dropped a little since the last 6 cyc was in place, this will be fixed in summer by some BC coilovers.
To save going throught the whole post ill update the first one.
Finished the New 3" Exhaust, all stainless steel tig welded i used a V-band to connect my new downpipe to the exhaust. Because this downpipe will be replaced soon for the new turbo.
Absolutely love the noise of it now, Just have one backbox in place.
Made a lower Coolant line to clear the alternator.
Got my hands on a new starter solenoid and brushes after the old solenoid decided it would be okay to stay locked on, Thankfully battery was low and it didnt start but none the less didnt want to take chances
Got a new alternator to compliment the start and put the 16 year old engine electrics to bed
Well this will have to be removed shortly
Along with this little nozzle restrictor that i removed while i gave it it's first full tank of diesel
Got a few odd looks while removing the nozzle restrictor and im sure ill get a few more when i fill it up in future
Changed the wheel to a genuine Nardi Deep corn ive been dying to fit in the car and also fitted the new paddle shifters while i was at it.
These still need to be wired in but that will happen shortly
Day time shot as is, im not happy with the bumper as i cut the hell out of it to fit the cooler and clear everything, I think next up ill fit a stock cooler and heat the lower pieces with a hot air gun and shape the bumper to clear the intercooler end hoses.
Car is in limp mode as it stands but my engine tuner emailed me a "New" map that has all the smoke/torque limiters raised and also the limp mode fuel tables replaced with new ones and a little more.
Car runs well but only creates boost after 4k when the stock wastegate cant flow anymore.
So tonight i wired the turbo up to my arduino 722.6 controller and set it to 1bar for 0-100% throttle and the car flys.
Still have the tacho / rev / coolant and few other lights to wire up on the cluster but so far so good.
Tacho is easy just 1 wire from the abs, for revs i will need to build a vr amp circuit but also not a big job. Rest is just wiring direct to the clocks
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Been holding off on this post for a while,
But finally making progress. Not due to there being so much work, but back to me me having time.
To begin a chose an is200 for this engine not the other way around. i did consider Nissan skylines and silvias etc.
Only because i didnt want to have to swap the sump or modify them.
I also didnt want to have to modify the subframe. My plan was to bolt the engine in with as little welding or custom fabrication as possibly.
Im not worried about custom oil lines, coolers plumbing etc.
I bought an e300td crashed and stripped what i needed from it.
Then got a lexus is200 drove it for 6 months then sold the engine, gearbox, ecu for what the e300td cost.
I sat the om606 on to a spare is200 subframe and realised that everything cleared perfect. Not only this but it sat on its own mounts in the perfect position.
Any further back and it would foul the firewall and further forward and i would have no radiator space. it also lined closely up to two holes in the subframe. So i got two stepped spacers made up and bolted the engine in place.
Needed to get 60mm brackets made to lower the anti-roll bar. But it is still above the subframe and acts as great protected for the front of the om606 sump.
Decided to use the stock gearbox mount and plate. and made two brackets for the plate. These alloy brackets bolt to the lexus body and the plate bolts to these. Easy so far.
Sent the prop off to get redone for the 722.6 gearbox.
Removed the viscous fan, fuel filter housing, fitted a new waterpump, serviced the engine. ran a new fuel return line through a vapour line on the is200 as it runs a returnless fuel system. mounted an x5 filter inline also.
Then got a bracket made that bolts to the EDC pump and allows a banjo fitting to bolt on.
Bolted on two oil coolers one engine the other gearbox, Got some lines made up for these. originally planned on a oil thermostat inline but was advice the om606 already has this, making that job easier. Fitted a return line from ps pump to rack and got a high pressure line made for power steering
The coolant lines are all custom but nothing fancy just 16mm alloy tube and some 90 bends.
The radiator line are a little harder. lower line is a reducer and a stainless piece a made to clear the alternator. The upper line for now is a basic join but very tight so this will be changed when i get an alloy radiator and relocate the upper hose outlet.
Inter cooler was supposed to be a 600x300x75 nice big one but the height was far too high for a lexus bumper leaving 30-40mm sticking out the bottom. So i then fitted a 550x240 instead fits nice although today the bumper got a serious shave to let the air in.
The stock ecu was socketed and a cr1 immo chip was fitted and one chip reprogrammed, so it started first turn every time now.
The original is200 throttle cable was fitted to the e300 tps sensor with minor work.
The ecu and glow plug relay both fitted into the is200 ecu box with some trimming inside but not obvious outside.
The vacuum pump is now plumbed inline with the brake servo for assisted brakes.
The bonnet was notched slighly on the drive side to clear the front of the cylinder head.
Still need to make an exhaust for it but have 3" and 80mm stainless for that.
Ole jefer 722.6 gearbox controller is fitted and tapped into the tps sensor.
The e300 shifter was cut down alot. and bolted to the original shifter bracket then fitted in place.
The shifter shaft was shorted and rewelded, then after i fitted the controller i set the length so each PRND was in the correct slot.
The stock turbo is fitted but the wastegate vacuum is not connected.
Also the egr is blocked at the exhaust and the original egr valve has been replaced with a 2" alloy inlet.
The maf and egr are removed so i presume the car is gone into limp and wont boost either way.
The is200 fans are run off a radiator switch so 2 12" fan where mounted to the front of the rad and wired in.
the overall goal is 400-450hp with a broad power range,
To achieve this is have an 8mm Dieselmeken EDC pump good for 170cc
a he351ve turbo with a can controller i built.
I also have now a 50trim t3 turbo and two wastegates. supposed to be a 60mm but allows 2" pipe and is measured at 44mm internally.
Still need to get a manifold made but got the flanges i need laser cut.
the ecu will be remapped by a friend.
Im not expecting the stock gearbox to last long, so i have an e55 amg gearbox with blown oil pump, and a 270cdi gearbox.
Im hoping to make one good box from the two they both cost the sum of €50 so there definitely worth a rebuild.
The is200 rear diff is stock and not known to handle abuse or power. so im looking into different options is220d / is250 / is300 and also isf options are being looked at.
Ill get all my pics uploaded soon and post them up, i know no good project is worth anything without them.
But today i got to drive the car be it just under low speed with no turbo spooling but a good start.
The poor front shocks have dropped a little since the last 6 cyc was in place, this will be fixed in summer by some BC coilovers.
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