just finished intake port+polish project - Toyota Nation Forum : Toyota Car and Truck Forums

Xevuhtess77 · 09-08-2004, 01:28 AM

finally.... after like 5 days straight of working on this, i finished it and got my car back together and running. sorry that i dont have pics, my mom has the digital camera on vacation right now. i used a tungsten carbide cutting bit on my dremel to do the grinding (which works reaaaaaaaaally well).

the parts i did grinding work on:
intake plenum-airflow divider right after the throttle body, mating of runners with intake manifold
intake manifold-mating of runners with head
head-mating of runners with intake manifold

the parts i polished (sanded using 80 grit sanding wheel):
intake plenum-air chamber, mating of runners with intake manifold as far down into the runners as i could reach (about 4 inches in)
intake manifold-runners all the way through

i followed the re-assembly of the engine with a coolant flush and fuel filter replacement. i also used some copper piping to bypass the coolant line that runs through the throttle body, so as to keep the throttle body a bit cooler. trying to get the car to start was a little difficult, most likely because the injectors might have been a little clogged with this white powder crap that developed everywhere while soaking the parts in degreaser. the engine would keep cranking to try and start, but wouldnt because of the injectors and because of no fuel being in the lines after being taken apart. after a lot of cranking it finally started and ran VERY roughly and slow, like 300rpm. i realized i had left a sensor or plug or some sort unplugged on the throttle body and that smoothed the idle, raising the rpm to around 600. just letting the engien run got the injectors unclogged and the engien eventually came to a smooth normal idle.

though i did limited amount of driving, power gains are definately noticeable. most noted is in the midrange, around 3500 or 4000 rpm and up, the car feels like it pulls a bit quicker. the gains in power are very linear feeling too, definately gains in all ranges. climbing through the revs is a lot smoother feeling and sounding now too. the idle is silky smooth, a big improvement from before the project.

i didnt have time to take off the heads and work on that cause school starts in two days

next chance i have some time off i want to work on the heads, and the exhaust manifolds as well.

im mostly overjoyed at being able to take apart this much of the engine and getting it back together in working order with the low amount of car experience i have. i definately learned a lot from it. got a bit quicker of a car out of it too!

***2wickedtoyz*** · 09-08-2004, 07:52 AM

your welcome

i bet when your car wasn't starting you got freaked out and when it wasn't idleing

what degreaser did you use? i used mean green and it didn't do that.did you put a filter inbetween the pvc lines and what not?

Xevuhtess77 · 09-08-2004, 09:38 AM

yeah thanks for all the help 2wickedtoyz, toyrme as well

i used purple power degreaser cause it was like half the price of simple green.

i didnt put any filters onto pcv lines or anything like that cause i needed to get the car back together as fast as i could. im going to do that some other time

i did some more driving this morning, i really like the smoothness of the engine now and the slight gain in power

Toysrme · 09-08-2004, 11:12 AM

YVW man! Just proud you got it done and did such a nice job of it! Since noone could help me in my problem getting the heads off; I'm having to postpone a full P&P to another time also.

I'll get some pics up when the rain slacks up enough to get me a chance to get everything back together.

ens · 09-08-2004, 06:50 PM

nice

CrawlingEye · 09-08-2004, 08:02 PM

lucky you. Anyone have DIY pictures of porting and polishing?

I've been considering this but am far too nervous that I'd screw it up.

Toysrme · 09-08-2004, 09:23 PM

Give me a few days minus even more setbacks and I'll do a partial write-up on it.

CrawlingEye · 09-08-2004, 09:39 PM

Well, If one of you could IM me on AIM and explain a couple things, that'd probably be all I need (NoPointSurrender's my AIM).

I'm just curious of a couple things. I have a 5SFE, not a 3vz, so there's obvious differences.

Xevuhtess77 · 09-08-2004, 09:58 PM

i added you to my buddy list crawlingeye. there really isnt much to write about for a diy port+polish. just as long as you understand the principle of why you're porting and polishing, you'll know exactly what to do once you open stuff up cause you'll see all the mismatched ports you can work on

CrawlingEye · 09-08-2004, 10:27 PM

Quote:

Originally posted by Xevuhtess77
i added you to my buddy list crawlingeye. there really isnt much to write about for a diy port+polish. just as long as you understand the principle of why you're porting and polishing, you'll know exactly what to do once you open stuff up cause you'll see all the mismatched ports you can work on

That's part of what I need to talk about. I'm new to cars (kind of), but I'm a quick learner and a DIY person in many things (computers, audio, etc), so I'm trying to learn as much as I can, and so far it's been easy, but no one has ever posted any intake manifold port jobs that they've done on a 5SFE, so I'm a bit unsure, my haynes manual has helped me find how to take out the intake manifold and so on, but it doesn't say (don't laugh) which part is the runner and so on.

I understand the intention of porting and polishing is to remove any casting defects and to smooth the surface, but I do not understand exactly how to go about it (as explained above).

Toysrme · 09-08-2004, 10:42 PM

My AIM is in my sig for a reason guys.

***Lauren*** · 09-08-2004, 10:51 PM

Can't wait to see it!

MadDawg · 09-08-2004, 11:03 PM

take more pictures

wontonjohnny · 09-09-2004, 12:15 AM

Quote:

Originally posted by Toysrme
Give me a few days minus even more setbacks and I'll do a partial write-up on it.

awsome .... quick question, can the gaskets be reused???

Toysrme · 09-09-2004, 01:13 AM

All the metal gaskets can. The problem I had on my '93 was that knowning I had a full engine set on the way I wasn't overly careful taking the gaskets off the intake chamber. Such as the TB gasket, EGR, idle vac control, coolant lines. I think I broke, or damaged every one comming off. You could if you were careful.

IMHO you only need the EGR one, the intake air chamber & throttlebody stay cold enough so that RTV wouldn't remelt. The metal ones are good for reuse. Xevuhtess77 put coperkoat on his.