Fuel Tank Replacement

Fuel Tank Replacement is the last thing I could think of. Unless it happens in the most awkward time. We are just getting ready to head back to our home town from Bandung about 15o km away, and since it is lunch time we are having our meal peacefully. That is until a strong pungent of gas / petrol smell lingering to the air.

To make it worst it is just filled up to its full tank capacity, and apparently the fuel sips out just as fast as we are drinking our last sip of orange juice. The thought of hazardous highly flammable gas leak is my worst panicking nightmare.  

It turns out that since this Classic 1997 Accord or known elsewhere as SV4 Accord has been left unused for over a year period with its fuel tank full, the low quality and corrosive 88Ron fuel has damaged the upper outside tank surface. 

And recently I have switched to 90Ron to seek out better performance that triggers surface rust getting into deep within the cross section of metal causing small holes enough to leak out..

Despite of its 20 maturing years old age the SV4 is still quite a joy to drive, 145 hp is not that big horse but it manages to lead the traffic along our extensive Toll road to and from Bandung. Especially important we need that much horses to climb around 500 meter altitude within the last few sections of Purbaleunyi Toll.

Though not as mature compare to our e28 BMW Project Car its chassis is nevertheless quite capable in dealing with uneven surface which hampers most of our Toll Road. A secure poise and handling with comfortable old fashionable style conventional automatic shifter is a blast performer than today CVT counterpart. Often a CVT equipped latest car is trailing behind running out of breath in those ascending sections.

As soon as we head back to our Hotel and unload all of our baggage the SV4 is getting ready on the hydraulic post and down is her 55 liters of fuel, the lowered tank reveals the damage. Due to time constraint we manage to just cover the holes with the strongest glue that we could grab for temporary fix.

And that is exactly 3 month ago today, I then never fully fill up her tank and just 2 weeks ago manages to get a 2nd hand Fuel Tank Replacement.

Fuel Tank Replacement

Saving on maturing SV4 is one thing, yet saving a good reliable close to perfect running old car over purchasing a new one is entirely another dimension. Betting on keeping Reliable 97 Accord over big saving on Chrysler car prices....wouldn't you agree!?

There are no less than 4 replacement Brands in US, should you need one ; here is my tips on Classic 97 Accord Fuel Tank Replacement!

Getting On The Stage IIMS 2015

just photo materials e28;

Luckily from the beginning of this Resurrection Project we have opted for OEM look that the original ground clearance allows no damage when we transport to the stages, its Front Lip Spoiler is intact. Saving years of Project Car is one thing, yet saving a good reliable car building over purchasing a new car is entirely another dimension. Betting on rebuilding e28 BMW over big saving on Chrysler car prices....wouldn't you agree!?

Upgrade Your Tires

Adopting High Performance Tires for your daily drive is a mere step to implement tips for easy modification (upgrade), furthermore when you are after for the ultimate overall look on your car, attractive appearance is a flip away from factory standard looking Wheel Rim and Tires combination.

Aggressive big wheel rims mates to lower ratio High Performance Tires will easily turn any car into another dimension, the biggest rim with the lowest ratio available.

Though the best performance might be the other way around to the best looking appearance, likewise sporty handling as opposed to comfortable ride. The most challenging parts is to decide which set of combination of wheel rim and tires to suit your final objective. A compromised ride and handling objective may not necessarily turn your car look as aggressive as you possibly wish for, but for a daily drive car is the best option to choose for.

Country road quality may be sufficient to some, but varies accordingly and most part do not even meet basic standard condition whereby certain states or provincial regions have tarmac or asphalt top layering with often pothole here and there. Worst some countries do have pothole and uneven surface along their toll road section . Whichever you are driving the choice of wheel rim tire combination plays important role in guarding your safety let alone performance oriented driving.

Those driving on 40% sub par quality roads must adhere safety practice, at most 55, 60 or even 65 tire ratio should be opted for wise choice selection. Expensive wheel rim would not be suitable either, unless the driver knows intimately her car and the road she travels. Today production cars are equipped with lower ratio than the above choices rendering soaring high tire maintenance costs.

Costs which reflect not only rims and tires but may extend to steering as well as suspension replacement parts! Depending on your application we have a few Wheel Rim and Tires configuration to adopt as real scenario example cases;  50 ratio on small city hatchback car, Daihatsu Sirion or known as Perodua elsewhere. There is no noticeable grip improvement albeit slight better straight line stability on high speed driving, but consequently ride quality is rapidly degrading to harsh on bad surface. (P205/50R16 : Plus 2 Upgrade)

60 ratio on small minibus, Suzuki APV. Larger 2" rim diameter to 16", initially intended for higher ground clearance. Better stopping distance with slight ride harshness on uneven surface going to worst on pothole. Typical Ladder Chassis and rear leaf spring for more rugged driving and higher cargo hauling capacity enhances slight jumpy right on the edge of fairly close to choppy but surprisingly still better than that configuration of Sirion, yet on full cargo haul it somehow dampen a bit. (P205/60R16 : Plus 2 Upgrade)

65 ratio, 1997 Honda Accord on original OEM Rim also higher ground clearance purposes. There is no difference on either ride nor handling, certainly this car has much better chassis composure. At smaller track width of 195 wide the ride seems to be more civilized. Accordingly if we stick to 60 ratio with 195 wide, grip gain objective is not completely forgone with reasonable ride trade off.  (P195/65R15)

Certainly a suitable configuration may depend on your individual taste, accordingly considering my own cases above, preference, driving habit and local public road, the best objective for balance ride and handling seems to be retaining the original Wheel Rim and then merely Tires Upgrade!

Starlet Ignition Breaker Points

Recently our youngest son has obtained driver license and since he needs a decent reliable wheel, we embark on searching for one. As he wouldn't mind driving a stick shift a proper three pedals Classic Car could be the obvious choice. Fortunately a cousin has put up for sale a straight original 1 Ltr. engined 1985 Toyota Starlet!

Though numerous works done on this Starlet amongst others such as chassis, alternator,  cv joints, top cylinder gasket etc., Air Con, the most important work is and as my Tips for Easy Modifications is on its ignition system.

The OEM Starlet Ignition Breaker Points has become rare these days as well as risking tear and wear in the near future we opt to modify and upgrade to CDI. The upgrade will facilitate a trouble free motoring without the occasions of resetting the breaker points gap now and then, it also allow for higher Voltage capacity Ignition Coil. Canadian made Pertronix CDI is our choice as it is a lot affordable than the OEM part. 

Pertronix CDI for Starlet

At less than mere 50 bucks the CDI installment is straight forward DIY for most home garage work as simple ordinary tools are required. Just throw away the points and capacitor, then replace the new module inside the distributor is a snap!

There is a catch though as there will be wiring from module to the control unit rendering dissaray looking engine bay, but it doesn't bother us. Most importantly it enhances smooth pick up performances!  

The small city car has currently clocked 264,000 kms, yet it still runs great with compliant and comfortable suspension. It is designed to be a city car anyhow and compares favorably at par with the latest one, but built quality may exceed the current cost saving mass production units. Likewise on the aspect of NVH, there is subdued tire intrusion noise, on this car we have yet to replace most of its engine mountings, yet overall engine vibration is quite minimum at bay from passenger compartment.

Another upgrade is the after market Tachometer, a necessity to tinker with Carburetor setting as the engine is now equipped with larger capacity Alternator as well as to cater Air Cond load and perhaps as our son wishes a proper sound system package later on.

Toyota Land Cruiser fj40

Blazing headlights upon volcano spitted sandy seas around 4 am is a fantastic experience amidst hundreds of Toyota Land Cruiser fj40s racing to the top peak of Mount Bromo, the objective is to get the best standing position on high rising sun rise viewpoints. A good clear sky is mighty bonus since the weather changes rapidly at this height altitude fairly close to 3,000 meters.

The 2F engine provides ample of huge torque rich right at the bottom, though on occasion shifting 1st gear is needed to acquire the basic instinctive Top Reasoning to Emulate Muscle Car. At this dizzying height terrain with twisty path you might as well forget the advanced Vtec, Vvti nor Vanos technology.

Simple 80's Carbed 2 valves per cylinder engineering marvels sing the best, yet I admit actually Diesel unit is more suitable. Actually it only accounts for less than 10% of the whole population of local fj40 association, obviously preferring more Horsepower figures. Pooweer! (As former Top Gear journalist Jerremy Clarkson used to shout as he drifting around the bend).

When the holiday peaks the whole Land Cruiser population close to 500s is out there commuting at least 2 tourist passengers with its max carrying capacity of 6 often more as the roof top is removed, bear in mind the ambient temperature is hovering around 10 degrees Celsius. Yeah not a good idea!

Exhilarating Driving Off Road >> Driving Off Road Guide adventures

Accord ac Unit Overhaul

A properly functional ac Unit is a great necessity, just imagine driving in humid sunny day without it! Cool air blowing helps a lot to drive in heavy congested traffic, we have all year around these typical driving scenarios. How to tell that your ac Unit needs servicing? 

 In fact when is your ac Unit last service schedule? Does your Evaporator clog like this?

Accord ac Unit Overhaul

No blowing cold air?  Pugent diesel smell from the next lorry intrudes? Forget about those Performance Tire plan, instead overhaul your ac Unit! The clogging Evap has necessitates my Accord ac Unit Overhaul. Don't ask when it is last serviced, judging by its appearance perhaps never since it is newly acquired way back in 1997!

accord denso evap

Apparently the poor old denso evaporator has since been visited by and made home by mice car aliens. Denso Evap is quite popular as OEM clearly evident to our Classic 1997 Honda Accord long term project.

Clutch Replacement

Back in the day of simplicity, a Clutch Replacement is much less of a headache than even the mere Performance Tire upgrade on your modern car today; it is all working around pure mechanical principles.

Here is a schematic diagram of such simple mechanical process depicting the main components of manual transmission Clutch and their functioning purposes. Though enabling torque to be transmitted to the drive shaft requires several physical chain reactions, it essentially starts off with applying pressure on clutch lining to touch the rotating flywheel.

designated friction process momentarily appears between the two components; it begins with sufficient friction forces to allow quick engagement and then most importantly to the normal holding forces existence during the engagement period, which where the designed amount of torque being produced can be transmitted through without any slippage.

Material selection and design calculation is mainly focusing into two critical functions, namely the onset and during engagement, taking into account the worst scenario of torque load being transmitted.

This actually necessitates the engineers to calculate other impacts such as stresses, strains and thus torque transmission losses being generated, but it may extend also into the area of designated parts lifetime as well as economic senses from the manufacturing perspective itself.

Generally speaking Clutch Replacement is dictated by this norm apart of the daily drive abuses.

When you are driving on ascending section of the hilly part of your town on the way to the favorite lookout point, the engine works the hardest to overcome the load, the optimal torque rather than horsepower is the key to ensure you can arrive at the spot where the city view is at its best. There are certainly many considerations to design a suitable Clutch to suit the required application with specific holding-capacity.

The survival of the fittest does matter for the material selection, the ability to provide certain calculated friction forces from the clutch lining material, its useful working friction ranges to ideally suited engine and load characteristic. Cargo load requires huge amount of torque at low engine speed, a characteristic normally belong to big displacement engine or diesel powered vehicle. A speed demon load on the contrary requires different kind of engineering parameter.

This ongoing engage and disengaging processes follow the above mentioned Mechanical Principle throughout the whole of your driving period, all the way to the top of the lookout point and beyond, working out the shifter has become the reflective chores to your limbs. That is until the invention of Automatic Transmission.

As the technology advances so does the demand for ease of shifting the gear, the Automatic Transmission could now shift itself based on the load creating nice comfortable driving chores.

No longer is a driver’s focus being distracted by the shifting process, more concentrations toward the condition of the road ahead; a real bonus as perhaps representing by the long by gone jargon of “Passive Safety System”.

In addition to have multiple Clutches, today modern Automatic Transmission also consists of complex computerized electro hydraulic mechanical devices lumped together that works upon various sensory readings. A number of systems have in fact can have the flexibility to adapt to your personal driving style. Simplicity is simply the bygone era; Clutch Replacement is now posing a huge big headache.

Mercedes Benz C Class a Forgone Over Engineered Era

After the production of the much praised and legendary W201 and W124 ended, Benz decided to follow the then cost cutting measures trend widely adapted by most car makers in early 1990s: Leaving behind the famous “Over Engineered” marketing term and thus its heritage traditional production method. Certainly with the exception of Its bigger brother the G Class, for obvious reason look for past article on Mercedes Benz G Class Accessories.

Mercedes Benz C Class almost revolutionized Benz character to follow its rivalry’s dynamic driving machinery, the BMW. It helps the marketing sales target at the cost of Benz purist who puts reliability traits above all. The evidence is quite bewildering, a large number of newer Benz taxi has spent more time in the workshop than the W124 counterparts, it is a harsh reality that most German taxi drivers facing then.

When the heavy seasonal flood hampers most of Jakarta and into a parked W124 in a private garage, it only requires wiping off the excess water and moisture. As the ECU is kept in a water tight compartment the car starts off immediately with no problem at all.

It’s the classic consumer behavior dictated by Manufacturer in the long run strategy! Technology-wise the computer is now in charge for the most parts of driving functions; combustion process, the controlled stability and other enhanced driving comforts and conveniences. Including individual driving style, motorized trunk access and lastly perhaps rendering careful battery replacement; the buffer memory stored for ignition mapping. Replacing battery without caution may result the car to refuse to operate.

Imagine turning the ignition key with the new battery, but the car could not run whatsoever unless the “engineer” not the mechanic puts the memory back on! The automotive wiring now boasts a system called Bus system allowing digital signal and DC current flows in an efficient manner unlike the system it has replaced. 

Less wiring length is required as it used to be, but analyzing electrical glitches requires specialized know how and dedicated training for each model and car brand. You should literary never allow a monkey attitude mechanic to browse your engine bay, unless you have expected for the worst.

 

And here is one good example of allowing a monkey tinkering your car electrical, the whole wiring gets a remarkable burning state. Now this Mercedes Benz C Class is in comatose albeit worthless vegetable car; Mercedes Benz C Class a Forgone Over Engineered Era

The good news is other C Class owner gets excellent donor car for affordable cannibal part resources! Then surely there is ample of remaining universal Car Accessories such as Floor Mats, Audio player, speaker, sport wheels and any Performance Tires set that come with them.

LED Angel Eye

The OEM equipped LED Angel Eye on your Rare and exotic car seems outdated? The thought of relentless car modifications haunting the soul to distinguish yours to other “ordinary” looking cars; if the pursuit of aesthetic rather than high performances, the original HID lighting Applications is one of the best places to start off.

Such option offers fewer drawbacks than any other modifications at least it would be much more environmentally friendly. Though a HID lighting projector Headlamp might impose hazardous glare to the oncoming drivers, its surrounding LED Angel Eye would not, yet could provide significant aggressive look. The BMW 5 series has pioneered this unique style since the early 2000.

Its available from the most advanced technology of CCFL filament down to the cheapest around from the humble DIY stuff LED illuminated clear acrylic/plastic rod to the alternatively fiber optics cables. 

The trick to make it lights up like the true 'Angel Eye', the latter two options necessitates multiple cuts (scratches) along the designated length whereas each cut is ideally measuring about 2~3mm apart. The multiple cuts creates the light to visually 'escape' the ring..

Certainly only those individual with highly craftsmanship could make the difference fabricating unique customized 'Angel Eye' regardless of material and filament choices, but creativity would also play an important role. Average technical knowledge in conjunction with artistic approach might evolve from a mere widely available aftermarket product. Hence improving the aesthetic look is virtually boundless.

All the better for a HID OEM car equipped with no LED Angel Eye, such simple 'Angel Eye' or ‘Eyebrow’ upgrade would be a great enhancement; as some folks might regard ‘Eyebrow’ upgrade as better stylistic trend alternative. 

Who would have thought that interior illumination style of the early 1970s could inspire LED Angel Eye craze of 2011? It is actually a rotating thermostat knob on an Old Classic W114 Mercedes Benz!

DIY Tools

DIY Tools might come handy for that precious Leisure indulgence time, and it would especially be very handful during the emergency which unfortunately happens at the worst possible moment. There are times for most of us to spent quality week end on our own classic car, not that it needs the repair, but rather to make it in tip top shape, such Tender Loving Care is indeed quite important for the Classic.

 

And having the right tools would certainly strengthen the excitement. Most Classics have little electronic or micro processor controlled gadgets if not none at all; relying the old but simple technology. Contrary to the recent advanced and useful HID lighting Applications it is purely mechanical system application, we could literally watch the whole process with naked eyes, almost anyway as an argument sake to distinguish very close to four decades of technology advancement; Hence simple DIY Toolsfor the reliable old engineering technology. 

An essential engineering parameter particularly for the non injection fuel delivery system is Vacuum Pressure, the very soul resources to maintain healthy engine. For an engine to idle evenly regardless of cold or hot state as well as ignition timing adjustments during either cruising or hard sudden acceleration and many other numerous functions in order to have optimum combustion process.

One recurring imminent case on a 1975 Mercedes Benz W114 280 is clearly depicted on the Vacuum gauge reading, though the Classic never in a lumpy idle but it is always uneven, it raises rpm on every few seconds then falls momentarily in perfect cycle on and on. Whenever the car is driven hard the frequency as well as uneven amplitude of fluctuating rpm is greater, necessitating Carburetor adjustment.

The Equus Gaugerepresenting simple DIY Tools clearly indicates late ignition timing and worst the car refuses to get into the green normal Vacuum Pressure zone. Both exhaust and inlet Manifolds have been reinstalled with new set of gasket, and there is no apparent misalignment on each part. 

Vice versa on the Carburetor sides, the engine has also shown no telltale of compression loss, as the 35 year old veteran has no trouble at all getting into 160 kmh furious speed territory, and there is hardly any noticeable alarming smoke coming out. In fact nothing at all, perfectly colorless out at the back end.

Lead Acid Battery

How many times have you encountered a sudden flat Car Battery? Worst mostly it happens during the rush hour. On older cars an experienced driver is generally aware the condition of its charging system. The main trouble is due to the inadequate charging current required to supply all those electrical equipments on your car.

Occasionally we do forget things as well; we are inadvertently leaving any of our Driving Light Applications on over the night, drawing approximately a steady at least 4 amp of current each hour. No it is not like that movie segment where a secret document is being exchanged in between cars with both driving light beam onto each other, and in a sudden twisted plot, it follows by gun fire exchanges with no survivors leaving the lights on until a passerby stumbles into the crime scene.

Armed with Jumper Cable it should be no problem finding a donor car source to supply that sweet burst of cranking ampere power to get the car wake up from its flat battery state comatose. No donor car? Push starts the car, that is if your car has manual transmission, but no jumper on an automatic car; well tough luck!

Following the principle of cost cutting measures many small cars are equipped with slight tinnier Car Battery capacity, thus the OEM Battery runs at smaller charging and hence similar discharging capacity, consequently upon heavy load there is more frequent cycle of charging and discharging which in turn shorten its life time. 

On a properly maintained Car Battery in accordance to the manufacturing specification it should last three to four years, but as electrical demand to power the current abundance equipment such as power windows, air conditioner etc., it is exponentially increasing, so does the need for bigger Battery capacity.

Though the common Lead Acid Battery has the advantage of short burst of current withdrawal for engine starting purpose, yet once it’s fully discharged it has inevitably suffered an irreversible damage to provide a full100% efficient charging and discharging cycle. It already goes in the failing down slope cycle, which new battery replacement is imminent.

As it has been said earlier there is a tendency for the car manufacturing in the spirit of cost cutting measure to equip smaller Car Battery capacity as the OEM part, and hence a significant Battery life time reduction. Such trend appears more profoundly on the lower class production cars, such as matching Battery capacity for a subcompact should have been 45 ah (JIS NS60) but instead they are equipped as OEM part a 35 ah (JIS NS40Z) Car Battery .

There is hardly a surprise for today’s Car that its OEM Lead Acid Battery could only last a mere one year period. Heavy current load at snail pace traffic could be the main culprit, as charging process at near idle engine revs only occur in the vicinity of 60% rate, the higher the rpm the closer to reach 100% charging rate capacity. The alternator is engineered to be operating at such condition to allow for its best life time expectancy.

Sleeper Benz

Not as many Sleeper Cars could be categorized as such belonging to those truly Classic Ride. Sleeper Benz is quite a rare European Classic Ride, in particular the W109-300SEL 3.5. Looking at its OEM Driving Light Applications of the bygone era, one simply wonders whether its barely than adequate lighting power matches its awesome performance.

Though finding such original accessories is another special tale tells story effort, it does heighten a sort of well integrated Classic restoration. The aspect of capable lighting might settle for the last priority. The Lumen (or luminous power) would certainly be revisited once the brute power of this W109 is being exercised quite regularly, only then the priority could be reversed dramatically!

This depicted OEM accessories fitment is certainly difficult to come by unless from a dedicated Classic Mercedes Benz Restoration Specialist which unfortunately only a few around. Authentic accessories on an original looking W109 would no doubt stir the emotion of anyone with Benz fanatics as the legendary W109-300SEL 3.5 is regarded by many as an entry level to Sleeper Benz following the limited production of 300SEL 6.3.

Contrary to the inadequacy of its fog lamp the 3.5L V8 engine should be sufficient to propel the sedan in a civilized rocketing speed manner. Matching to the speed legacy is its air cushioning suspension at all four corners delivering un-forgetful ride quality.

As many other restoration projects there are ample of hurdle stand in the way; the hard to get chrome ornaments inside the passenger compartment and outside along the body exterior. The hours spent to revive numerous mechanical equipments including the plumbing system to activate the air cushioning suspension, whether there is enough pressure circulating around or even some trial and error works to look for the odorless and colorless air leakage particularly at those plumbing joints.

Surely replacing the whole plumbing and fittings would solve the problems immediately, but the aspect of originality could not be neglected all together. Take for example the engineering design behind the approximately 7.2 L air supply canister seems a bit small to carry 2.5 tones burden. Would it be tempting to replace it with modern stainless steel container?

And what about replacing those aging pressurized plumbing system all together? It is obvious that where there is a pressure there is always a potential for a leak somewhere some time on even the best material available; once these factors are being fiddled around why not refitting a bigger air container filled with Nitrogen gas instead, as now a customary fitment to our tires.

No doubt there are many other ideas as well as how extensive such restoration job should be carried, making a hasty decision will definitely pose an irreversible drawbacks! Drawbacks which will linger to the rest of such restored Classic Sleeper Benz life time in coming future.

Door Handle Fabrication

Door Handle Fabrication may indeed seem an easy DIY fabrication task, as simple as having an Air Intake Modification to for example Leisure Drive own DIY Project Car 97 Accord, yet even some replacement parts are hard to get by for some rare model vehicles.

Door Handle Fabrication for the rare population W201 190E is truly the only option available over here. Only a small number of CBU W201 is imported to this part of Equatorial hemisphere. As a result no automotive shop is willing to fill up their inventory level with low value hard to break replacement parts such as this diminutive looking Door Handle.

A catastrophic crack has developed along the pivotal base rendering the Door Handle to be completely useless. Luckily a thin sheet of metal is able to be inserted with enough space to the gap between Handle assembly and the handle pivot forming a structural outer layer, a glue application together with few clamps will do the job.

For such DIY project work a Clamp Tool is quite handy indeed, though the uncluttered look seem distasteful yet it is fully functional. It is functioning at least temporarily till the replacement at the appropriate price comes around. Alas the opening and shutting a Mercedes Benz Door does typically require a slight of slamming effort, a bit more than other brand does.

Benz Toy

Benz Toy is purely the culmination effort for those car enthusiast freaks in order to have their own classic Mercedes Benz ride roadworthy as well as being sensible to maintain. Such innovation has long been regularly deployed to any Old Car for Beginner's rally car.

It is such a customary to have the latest suitable braking system to be fitted on the popular Corolla KE71 series for better rally braking purpose. Not much peculiar either for those old classic W108 Mercedes Benz 280S receiving Carburetor replacement from a Toyota. Despite of its bulletproof reliable W108 model, a long running classic Benz does suffer the failure of its two downdraft carburetors, eventually every two decades or so.

The replacement is sourced from a 1980s Toyota Crown 2.8L. Certainly a new adaptor is required as well as new Jet/ Needle setting. One carburetor settings is much simpler to attain than two, not to mention the long run Ease of Maintenance.

G Class Conversion Part 2; Toyota Engined G-Wagen

Similarly but not for similar replacement reasoning; the Prado engine conversion to a G wagen. The 1KZ-TE has slightly bigger capacity than the original 6 cylinders DOHC; it is merely a 4 cylinders SOHC 2982 cc 2 valves per cylinder turbo charger diesel engine, producing much less at 125hp. Yet its highly rich 287 Nm of torque peaks @ low 2,000 rpm is the main reason for tugging the 2.5 Tonnes G-Wagen, an ideal solution for stop and go city traffic.

Another bonus is the 1KZ-TE comes with the automatic transmission. The replacement engine was introduced way back in 1993. 1KZ-TE has already adopted the electronically controlled fuel injection, ETCS-i (Electronic Throttle Control System - intelligent) technology which is similar in basic construction to a modern gasoline injector, although utilizing considerably higher injection pressures, yet it is still an indirect injection engine.

 

As the factory boost pressure is set at 7.4-9.7 psi (51-67kpa), there is a lot of untapped potential to be further developed on this popular engine swap choice. There is bountiful evidence that higher pressure set up with the addition of matching Intercooler will achieve a similar power to the original DOHC power plant around 150hp as opposed to those engines fitted to its sedan sibling the W123 280E which rated at 185hp.

There is a another conversion involving further modification by fitting a dtronic Performance Chip as well as employing larger free flow exhaust system producing significant power and torque gain without degrading its fuel consumption, though a larger exhaust piping is quite difficult on the G-Wagen under carriage due to space restriction.

The 1KZ-TE is not sourced as a half cut; so consequently wiring the engine on the G-Wagen is currently the main challenge for our friendly Mercedes Specialist. Interpreting the available wiring diagram scheme does require time. 

Perhaps a typical trial and error implantation surgery will have to be implemented. For a start “Cuk Dewantoro” the owner of DCM Mercedes Specialist has already decided not to connect the EGR function for the sake of simple first phase surgery. Should the engine runs smoothly the G-Wagen might have a slight tendency toward high emission.

Complying with our lenient pollution rules will have to be postponed at a later stage, first thing first is to attain successful engine transplantation surgery. The local Police head quarter (not DMV) has recently issued that for every vehicle license renewal such vehicle must have its emission control sticker available. 

Yet FYI we need not to pass the strict Euro5 level as anywhere else, the majority of locally produced vehicle is still adhered to at most Euro2.

Pressing on to our conversion issue, though the 1KZ-TE is already mounted on the original G-Wagen engine mount, its transmission is not connected as yet to the Gelanden Wagen’s transfer case. The car has actually suffered a slight miss aligned main driving axle shaft. The DCM Mercedes Specialist “Guru”, Cuk Dewantoro has two main tasks in the drive train sector; first fixing this inherent G-Wagen problem (as I recalled we had to replace ours at the cost of 8 Grand US$ back in early 1990s on a 1986 GE280) and secondly fabricate new connection from the auto trans to the transfer case assembly.

Adamant to please his loyal client Cuk Dewantoro has already devised a plan to mitigate the damaging bank account effect. That is to fabricate 5 Tonnes Mitsubishi truck driving shaft to solve these two main tasks. The Mitsubishi has solid shaft where as G-Wagen’s is seemed to be a specially built with oil filled hollow shaft in order to have a dynamic balanced rotating shaft.

For those who has been driving the G-Wagen, it has very solid and rigid chassis, if there is any slight miss alignments, the chassis has somewhat successfully amplify such out of balance to reverberate through out the whole body structures. 

No doubt the fabrication process will be definitely subjected to a rather long trial and error works, which remains to be seen. Fingers crossed Mas Cuk!

Notice the engine mass center position has shifted; it is now located further away from the firewall bulk head as opposed to the original DOHC GE280.