Sam44

Also the same ems design as the ep82 and ep91 4efte JDM.

To setup idle: have the idle screw fully in.

Set the throttle stop to 850rpm. Engine running 

Turn the idle screw to 950/1000rpm, I use 1000rpm as base oil pressure is better and alot more stable. 

Now set the tps using a multimeter so the idle position just touches. And plug the tps plug in. 

We have found a timed delay between idle mode and acceleration mode/map on these ems types. So to increase response again you can set the tps so it's just off the idle switch this keeps the ems in acceleration mode. Setting up the tps/ems to stay in acceleration mode has no real affect on the idle, but does have an affect on mpg & emmisions, it still idles nice. 

You will how ever need to drimmel/modify the tps base cam at the wot position, because you have now advanced its position. the wot position is now going to switch on early before throttle flap wide open position. You need to synchronise these 2 elements. On the factory ems the wot position switch once activated overfuels for safety killing peak hp. This is set to come on just before the throttle valve is in the wide open position. 

Be warned this is a critical area of the map. Use the wot switch, never delete it, but good gains are achievable in this area of the map. 

The ae101 ems does not run a chipped key/factory immobiliser so a aftermarket immobiliser is also recommended to protect from theft. 

More information to come on ems pin swaps. 

The pin swap needed to get the ae101 4efe ems to run on the ep91 4efe is in this topic. (It's near the end of the topic).

you also need to delete the tps idle position on the bigger 4efte throttle, to do this I simply cut the green&red wire at the tps. 

Do not cut it at the ems side it will stop the map sensor from working. 

after installing the 4efte larger throttle and tps on the ae101 ems using the ukdm ep91 4efe wiring, we noticed that the vehicle would cut the fuel pump if the idle switch was used/activated another reason for the idle position delete. we are currently looking into why this would happen. we have carried out a dtc (blink code) read out on the ems and no faults are showing. time to dig into the wiring. 

update on the ep91 4efe wiring/fuel cut on 4efte tps idle switch activation. the map sensor uses this tps idle wire, we can see now why fuel cut would happen also how the 4efe factory tps affects fueling. we could see something affecting the map sensor signal as we ran the 4efe tps and ems now we know what was happening.   

The idle up thermostatic valve on the 4efte as well as the 4efe throttle heater run at engine coolant thermostate temperature a massive 89deg C. By removing this you gain a good chunk of torque especially in the winter months. 

Be warned mpg does suffer. This is the reason for the heater to target mpg in my opinion. 

We are getting threw the errors we are finding 1 by 1. The engine runs so so smooth and throttle is very very responsive now. 

We have also taken fuel temps for the first time this year. Last year at the same time we recorded 37degC in tank temps. We have just recorded 11deg static temps with the engine running for 40min. we are hoping this to drop lower when the vehicle is in motion using the fuel cooler. 

So it seems I can't keep dan away from the starlet.

 we have decided to install the e11  88hp corrola tubular inlet manifold running along side the 4efte higher lift inlet cam.

The engine torque does not drop off like seen on so many 4efe due to the 4efte cam, but it does flatten out at around 5krpm. This is due to the manifold limiting air volume delivered to the engine.

we are going to install the bigger 4efte throttle body to allow more air volume threw. because of the difference in tps we are going back to the gen1 4efe ae101 ecu 

Also we can achieve a better mpg using the ae101 88hp ems, plus the lamba closed loop operation is not as responsive allowing us to run it constantly. 

Installation of the ae101 4efe 88hp ems and bigger 4efte modified throttle body.

This ems uses a switch type tps rather than a potentiometer type which affects the fuel table/map. (fuel trim) 

The UK ep91 4efe ems 78hp low torque,  has the same plugs there's just 1 wire to swap. I'll put up the how to on here. 

we do not use the idle switch position on the tps (because it has a noticeable delay going into acceleration mode) i simple cut this wire green and red at the tps plug.    

Below is the early gen1 ae101 corrola ems around 1991 to 1994 88hp, and larger 4efte throttle body. also in need of a good clean. 

Here you can see the adjustable switch type sensor. Look at the mounting points. Also note the plastic cam type operating base that switches the center pin output to either bottom pin = idle mode, or top pin = input wot conditions. 

The wot conditions do come in early not exactly on wide open position of the throttle valve so we will modify the cam on the base plate so to sink in the throttle valve and switch. 

Idle position 

Wot conditions

Bigger 4efte throttle body modified. 

Here is the factory idle screw which we will use because the throttle idle up heater element has been removed and blocked off

Plus the throttle stop screw which we setup to reduce the pressure difference between pre throttle and post throttle running conditions, this will limit the chance of intake air stall (flat spot on initial throttle drop). 

There is some modifications needed to the manifold throttle mount (opening out of the main intake port internal diameter), and a base plate needed making for the throttle body in order to use this combination. 

this relatively easy install will help lead us in the direction of how we will need to design the manifold/power box using the 61mm larger twin throttle body. im trying to keep the small plenum chamber. its fantastically responsive.   

the audi twin throttle also has a switch type tps.  with no idle switch. 

Doing a grand job there. Incredible little car. 

Yeh you can use the dump line port in the manifolds plenum chamber for that. 

The canister is there to draw out and store fuel tank fuel vapour then releasing the vapour back into the engine. Charcoal is a very dry material. The fuel tank breather is a closed system for environmental emmisions. 

• They do modernise it for sure

Oh yeh. Keep the progress coming. 

It's coming up to summer skinny, play time. 

There's a change of plan on the turbo choise. 

I'm going for the tfo35 with the larger exhaust turbine using a tdo4l 13t cast factory compressor wheel and housing. 

So a tdo35 HYD on a externally gated manifold aiming for 160hp low boost fast spool high high torque. 

The 1.5ltr engine, cams (5ehfe) and inlet (4efte power) should provide kick ass peak torque, with the longer stroke engine providing great torque threw out the rpm range. This will however affect turbo spool creating a delay in the turn on time. The reason for a hyb turbo. 

I reckon at around 7psi (low boost) on the setup the 5e 1.5ltr engine should produce this hp and spool up around 2.5krpm.

It will pull to redline, I'm  hoping the torque will not drop away either at any point. 

I'm very excited to collect it. 

3 hours ago, jellybaby said:

Have u gonE cop? 
if

so wepr sell dizzy blanking caps 

no ive put a higher kv external coil on the normally low kv internal coiled dizzy of the ep91 uk 4efe. if that makes sense. ive had to modify the original dizzy cap. dosnt look the best at the min. im just after dressing it up. im running a plug gap of 1.1mm. 

thanks for the reply and suggestion. im pulling my hair out trying to find a 4 cylinder cover/bag. i might have to have 1 made at this rate. 

This brand FMIC do look tidy for sure. 

how are you. 

yeh im well chuffed its only done 49k miles and is clean. 

after experiencing the 4e starlet ive decided to hand in my company car that im paying a shit load for to be parked up and go for a rare toyota, of course boost the little bugger. the shape and style really appeals to me. very much like the honda dc2.

get a nice set of period wheels for it revamp the suspension so it rides like new and enjoy.    

despite the muck she look gooood!!.  

so today dans last day he has fitted the glanza electric mirrors and made/run a harnessed loom to the dash. i must admit these even still very basic are much nicer than the standard ukdm starlet mirrors as can be seen in the previous picture 

fitted the clear wing side repeaters.

removed the toyota molded mud flaps ready for the side skirts.  

and made a start on and removing the side bump strip tape left on the doors. 

he is just fitting the adjustable steering column at the min pictures to follow.  

i believe the seats  are out of a celica (fully adjustable). 

list of things still to do. 

1) free off polo 6n2 coil overs so they can be adjusted to raise the ride height (after the exhaust ground strike killing the flexi and high flow cat). 

2) get the car upto pirtex so all the fuel lines can be made up (high pressure connectors) after several slight fuel leaks at the joints. 

3) get the hyb tdo4l turbo sorted and back on. (the td05 anti surge compressor housing needs alttile work) 

4) modify the corolla inlet to house the audi throttle body+get a power box inter-cooler pipe made up (pre engine throttle pip section). 

5) fit the mr2/e11/corsa front brake setup fitted with the galant larger master cylinder.   

6) fit the engine oil cooler/thermostat.

7) pannel in the intercooler reducing air spillage maximising the exchangers efficiency. Also to wrap the intercooler piping in heatproof tape, as well as cut holes in the vin plate pannel allowing access/path for the engine bay air to circulate out over the screen, reducing bay temps + vehicle drag + helping defrost my screen in winter. 

design and implement an effective engine breather system my goal is to use it produce a constant crank case negative pressure promoting piston ring seal and reducing piston double pumping ( the affect here is to help the pistons move down the cylinder bore improving engine efficiency. 

yeh that would be fantastic. a great bunch of lads and ladets on here. ive done my stint away with work for at least the next 2 years. lets do it.  

from what i can see there are quite afew in the north west. 

gt turbos/glanza

ep91 starlet + turbo

starlets 

ive just purchased that front bumper dam (splitter) £500 GULP!!!!. 

wait till you guys see the tacho head attack (mph build/times) from standing its got real nice grip and the 6 speed box hunts down them speeds. 

 that is smart, thanks so much it will save me alot of time. 

thanks so much. ill get it now. thanks for the advance idea also i really like the color and idea. 

morning burty mate. cheers. im going to try and go as advanced on as many items as i can on the vehicle. 

ive had many many cars ive modded over the years but this little thing is really quite cool, and most of the parts are toyota bits. 

how are you and the family?. 

ive got everything crossed for that date, and yeh im going to do an advance tribute using the ukdm cd. at least if people see it and look up advance they will have an idea of whats under the skin. the color also suits the car, retro old school like me, haha. 

have you got any pics of the splitter. i need afew ideas. i can make alot of things fit im a wiz with the fiberglass, and body filler.  

im very impressed with them.

im also logging the data from the sensors to the gauges and there spot on. i had to fine tune the boost gauge. the alert/alarm/warning on them also come in very handy. ive also got them all on the same color and brightness as my stereo and dash lights looks smart. 

im very impressed with the hole car. very easy  to mod/work on very cheap and the performance so far has left me speechless. the setup delivers a constant hard pull. the inter-cooler im getting inlet temps around a steady 9 deg C at 7 to 8 psi. turbo spool was around 3krpm down to 2.5krpm with the corrola inlet, turns on quick. ive also got the throttle water lines removed.       

cheers pikey

the front bottom cross member has been modified with 2x arches wielded in 1 on the off side 1 on the nearside its a neat job it looks like it came with these in there. the inter-cooler literally fits in the space behind the bumper crash bar, its still in there.

i do how ever need a good bumper dam (splitter) to reduce the air going under the front of the car. the rear bumper being larger brings a large aero drag zone, like a big old air brake. i need to reduce this with the front ground clearance if anyone can give me any suggestions.    

thanks. i didnt want to put the pics up of the body until it was painted, but i do like the rear lights. 

here is 1 of the front  taken awhile ago the bumper has been smoothed over were the cut outs are. 

ive also just got a set of black glanza electrical wing mirrors for it today.

excuse the sealant on the dizzy cap (its certainly sealed) dans new to engine instant gasket. 

I'm after a dizzy bag/cover but the only one's i can get at the minute are for v6,v8,v12 engines (a bit big) 

The idea here with the cam belt top cover is to use fine stainless wire messing to neatly cover the cut out. Then I'll fit high visibility led light inside the cover to make the blue cambelt and purple top pully visable/highlighted/POP. 

This will then give protection and I'm hoping look smart. 

that is what i was thinking. what boost pressure was that at. 

are you running a hyb turbo if so which unit and whats the lag like?. 

i think ill get racetech to do my paseo ems and mapping. very impressive on a standard engine.  

me to hope its fixable but there are some good low mileage starlets out there at the min, some going for £400. maybe swap all the sr over to a decent shell.  

cheers dutchie. yeh the side skirts are needing modding (5 door) ill do these things. as well as paint the rear bumper black, the side skirts and front bumper are also black. 

yeh i would like to for sure but as soon as dan gets the weather hes itching to fit things (a young pup) hes really enjoying building the gt and starleto. 

i hate having parts laying around in boxes to be honest, they always seem to get marked or damaged. 

plus as soon as i land we can hit the harder things.

he does all this with a small halfords tool kit. gotta love these cars.

i am really home sick at present. the cold conditions are starting to bug me now.  

hoping to have the rear windows tinted by the time i get back also.   

so dan has been and fitted the clocks as well as the rear lights here is how she looks. 

im just having a sit down read now with a brew. 

fantastic stuff.