Its amazing seeing these major parts NEW, eg gearbox!
 

MANDALAY
... we ran my car without the water pump running a whole day ( to set up up cooling failure, ECU control ) at ambient temps of 36 degrees , the highest IAT's that were logged were 56 degrees Celsius ...

 
That looks like a very decent  result, my understanding is that a good benefit of a w2a IC setup, is that the volume of water is a great heatsink for absorbing the heat removed from the intake air.  I would guess that in normal driving where the power applied is not sustained for a long time, running the pump will not make much difference to the intake air temps.  The beauty of your setup is that you can easily monitor all these functions/data.  Would be good to report your findings on how the system behaves once its all up and running.
 
Cheers 

My car is running.  The pump was turned off so as to allow the MoTec control the engine in extreme circumstance of failure.
Yesterday with ambient temps of 16 degrees and 200 kms with a lot of power runs it didnt get over 34 degrees with cruising 25.
 
I believe the Barrel even tho it works is not the best which i will change and the Bosch pump also is slow with only 20 liters/min hence the Johnson CM90 pump which will move the water much better and quadruple the flow. This way i can get faster recovery and hopefully closer to ambient.
 

So i found a better water bottle to use for the overflow so i can relocate it to the boot left rear quarter panel. This way i can add a bigger Intercooler and wont have to worry about the bottle getting in the way
 
Looked everywhere for it but as usual Aaron at Lithia can up to the task :)

Its from a Supra TT and another great thing is that it has the float switch also. This way i can have a LED light somewhere up front so i wont have to pull the carpet to look.

Dang they should have had one on the OEM MR2 one as its near enough impossible to see.

Ill make a bracket and lock it in place
 

MANDALAY
... the Johnson CM90 pump which will move the water much better and quadruple the flow.

 
you wouldnt want the flow too great would you, otherwise the water will spend too little time in the HE to cool effectively?  
 
Cheers
 

Not the case , you would want the water to move a quickly as possible.
 
Speak to any of the pro shops that supply intercoolers and they will tell you this.
 
I dont fancy doing the lines again but they will also suggest to use  38 mm lines.
 
Its all about turbulence and moving the water as fast as possible

Just working on the layout of the pipes.

This time around im changing another item again. The intercooler.
With the relocation of the Coolant overflow bottle there is much more room for a bigger unit. While up to Sydney i checked out another brand which i like.

Plamaman. Its not round and rectangular with higher specification figures .
Going to get the core section then cast some ends for the air in/out so that they are aligned

So just to show a few things that im working with. The E153 has a different body for the speedo sender in the gear box. But its plug position is in the way for the intercooler as its at 90 degrees to the body.
 
So im going to change the top plug to that one of the S54 as it comes straight out
 

A modification i wish to make with my Idle Control Valve.

This is not intended for anyone running a stock Beams engine which has the MAF in place but rather those who have modified and gone FI with a MAP.

I made an interesting observation with 3SGTE's Turbo engines and right up to the 2007 Caldina that the air supply for the ICV is from the air box and NOT from the air intake to the TB.
Now is this because they are FI with MAP or is it because of the normal atmospheric pressure supplied from the air box ?
We all know that the Beams ICV and that of the Turbo can get blocked and have oil because the valve is at the bottom of the TB.
Well Toyota went one step up in 2002 with the ST246. So as this doesnt become a problem theY separated the TB and ICV which they repositioned it vertically on the side of the plenum.
Well this would definitely stop any blockage to the ICV and also as said the air for it is supplied clean atmospheric pressure from the airbox.
 
ALSO ANYONE WITH AN AFTERMARKET PLENUM COULD ALSO CONSIDER THIS



What got me intrigued is that Toyota i believe has pretty accurate diagrams for their parts. And low and behold it looks like the beams ICV in shape and also the 3 holding screws



The difference is that on the Beams the water goes in a chamber then through a pin hole then out where the thermostat valve is.
On the caldina it just goes in and out.
If you look at the Beams ICV there is the space for the other pipe but obviously isnt there.
Now when you look at the gasket the Beams has 2 smaller squares where the air from the intake travels in and out behind the TB.
The caldina because the air is supplied from the air box it just goes into the plenum.

So what does this all mean ? Well first instead of gambling and spending money on the Caldina ICV  i am going to buy the gasket and see if it lines up as the Beams.

If it does then ill buy the Caldina ICV And modify it. Close of one of the water inlets and run it like the Red Top with the thermostat.

Then on the TB ill close off the opening before the TB that supplies the air to the ICV .
Route an air supply to the ICV from the airbox. It will be post filter clean air under constant pressure and be on the blanking plate that i put on the air box where i removed the MAF.

No dirty ICV , no pressure fluctuations from the SC.

Well the intercooler place PLASMAMAN have been good to me by supplying me with the core and just tacked on water ends so that i test fit and work out the air end tanks.

I might be changing the top water end tank if there isnt enough clearance to the inlet plenum for the pipes. We will see on the week end







Here you can see the size difference between the 2 intercooler the core is double the size. More cooling and teamed with a water pump that has 3 times the flow the recovery after WOT should be faster and the extra length should also get the air temp closer to ambient

Spend most of today just lining up the intercooler.

Worked out how to bolt it down by welding some steel to the engine bracket for a solid mount. Double checked the clearance and looks OK

Gee that gear box is big its about 2 inches taller than the S54





Checked alignment , the engine bracket is the boundary for the fire wall down the bottom but up higher there is about 3 inches to the fire wall