Legnum – Broken again….

Buy a Legnum they said, it would be fun they said.
Missus gave me a call one night, said the Legnum was making some “Nasty bad grindy” sounds.
As the well taught chickadee that she is, she had already double checked fluids, wheels and the engine bay for obvious things.
It only did it while driving and it got worse the faster she drove, so she pulled over and and called.

Into the MR-S and I zoom out to to find her on the side of the road.
A quick look around the car myself and it didn’t show signs of obvious things (Wheel bearings, failed brake caliper, etc).
Told her to jump in the MR-S and I’d have a go at limping it home.
I made it ~200m before I pretty much determined the issue and accepted the fate.

A failing transfer case.

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Anyway, just thought, fuck it, send it and see how far we get, the less distance, the cheaper the tow truck trip.
Well it made the 20km trip home, but was very angry the last kilometer, every corner I could feel it binding the front end up and clunking.

So once again the Legnum is parked up…

Thanks to a member of the OZVR4 forums, I picked up a replacement transfer case, a pair of turbos (might help with that smoking issue…) and a drive shaft (I suspect the middle bearing on mine is worn as it clunks a bit).

But for now, we needed another 4 door car, that is reliable…

Maybe I should have just bought one of these in the first place instead of the Legnum….

Yep, a 2002 Toyota Camry V6 manual.
Last of the 1MZ V6’s and fitted with the much sort after E153 manual gearbox.
It handles like a bucket of shit with flogged out shocks (it does) and tires so hard it peg legs for days (in the rain you get keep it spinning in 3rd to limiter)
I do happen to have a TRD LSD that will fit this gearbox, so maybe, just maybe when the Legnum is sorted, it will get a gift of traction.

Legnum Diagnostic Tool

The 8th generation Legnum/Galant uses a really simple method to put the car into a diagnostic mode to flash out the error codes on the dash. You just put a jumper wire between pin 1 and 4 on the ODB2 port and turn the ignition on. However, I’m lazy and I’m over looking for the bit of wire I’ve left in the car and then having to awkwardly bend under the dash to insert it. So I came up with this solution.

Core Electronics sell the ODB2 connectors for $2.65.

The pins are neatly labels as well, I grabbed a pair of pliers and bent pins 1 and 4 inwards 90 degrees.

Then soldered an offcut of wire across them.

I will eventually fill the plug end in with epoxy, a small loop of string will be embedded to help remove the plug from the socket, it will also protect the pins from shorting.

Legnum Life – Error 61

Well it was a good run….

Diagnostic mode…

Error 61 – A/T ECU And Communication Lines (Torque Reduction Request Signal Line) System

Did I just buy a Golf R???
The light goes away after a power cycle, sometimes I can drive for an hour and it doesn’t come on, other times it comes on within 2-3km.
The automatic transmission drives well with no issues or oddities, so I’ve been partly ignoring it.

Legnum Major Service – Part 22

This week on Dragon Ball Z, Goku finally def………..

We try to get the Legnum registered!

The Legnum has been rolling around on some boarder line legal NT01’s since we pinched it’s tires for the GC8 one time. We the spare GC8 wheels were loaded into the back ready for the tire swap to happen again and give the Legnum it’s tires back.

Setting off for the registration inspection.

Being inspected….. And passing! Paperwork done, called my insurer, organized the required road insurance, next stop, the transport department.
(As this is an imported car, a lot of the features are not mentioned, so the inspector didn’t have to check things like the ABS or AYC were even working!)

And registered! Drove it home.

Now it’s all registered, I will now daily it for a bit to make sure everything is running well while I order the parts to fix the issues.
Only 14 months behind schedule…

But hey, as the motto says… ‘Sometimes maybe finish, sometimes maybe not

I’m calling that a finish.

Legnum Major Service – Part 21

The Legnum had a few dash lights on after getting it all back together, some I knew about (TCL Light), others were new (ABS). So it wasn’t likely to pass registration inspection without them being resolved. The TCL light was always on, so I put the car into diagnostic mode and counted the flashing patterns.

Error 77 –  TCL vacuum system or ventilation solenoid

This thing. A quick investigation with the multi meter determined the top solenoid was 0 ohms and open circuit.

I found that a local delivered Mitsubishi Verada had the same solenoids, but on a different bracket. $100 of ebay shipped.

They arrived, I fitted it, turn the car on, TCL light still on! Put it into Diagnostic mode.

Error 77 –  TCL vacuum system or ventilation solenoid

For fuck sake, threw the multi meter on the new solenoid, open circuit…. It’s $400+ for this solenoid brand new from Mitsubishi.
Going to let this one marinate for a bit ***

Next up was the ABS light, well after some research, it appears that when I put the new 98+ front up rights on for the Brembo conversions, it required different ABS sensors. I had just reused the ones I had, which it turns out are about 15mm shorter! So I sourced some second hand sensors from New Zealand.

Fitted them, ABS light still on, for fuck sake!
After pulling both sensors back out and testing them, I found that the front left sensor was buggered.

*** I think that marinating is done.
I decided to pull the dash out and I’d just pull the TCL and ABS globes like a dodgy bastard and deal with it later.

Oh look at that, there is a lot of missing bulbs…….

Pointing my workshop light into the back of the empty bulbs. I found a few blanks, which are reserved for features or functions this car doesn’t have and I then found the following.

Check Engine light… Oh.

AYC…. Oh

Skids…. Hello there.

I took the bulb out of the TCL socket, then put it into the AYC and then put the ABS bulb into the Check Engine Light.
Powering the car up in diagnostic mode showed some more codes….

Engine codes
Error 62 – Unknown
Error 71 – Vacuum Control Solenoid Valve System <T/C – A/T>    <—- The same code from the TCL light.

AYC Codes
Error 22 – FL wheel speed sensor system

Well I knew about Error 71 and Error 22, but the Error 62 is unknown and the motor doesn’t seem to have any issues.
#YOLO. I pulled the AYC bulb out and left the Check Engine Light in. It didn’t display any codes normally and turn off shortly after ignition is keyed.

In the next episode, we will suck it and see if we can get the Legnum registered!

Legnum Major Service – Part 20

With the intercooler finished, it was time to move onto completing the remaining items to get the car back together.

Sorted out the mounting of the bulbs into the head lights.

Replaced the mis-matched and rusty headlight bolts with some stainless ones.

Battery tray and mounts were refitted.

The bump mounts were rather damaged and caused it to sag at the guards. So I used a few scraps of aluminum to make a more supportive clamp setup for it.

Front end all back together. Some day I’ll track down a new bonnet, grill and bumper to replace all the damage.

Lights work.

Till next time.

Legnum – Intercooler Upgrade – Part 6

Picked up the 135 deg bend from AutoOne today, so lets get back into this!

Hole saw through the tank.

What a mess… lol

Put the new inlet in and mark it

Pull it back out and trim

Trimmed and deburred.

Inlet pushed back in and ready for welding.

Welds are still sinful, but they do look less horrible than the last lot.

Back into the car, time to fit the silicons.

The 90 deg bend on the hot side will need to be replaced with an uncut one as it’s only getting around 15mm of grip onto the hard pipe. The 135 deg bend need 20mm trimmed off the intercooler side to fit properly.

The crash bar fitted back on, the intercooler sits way behind it now. I could honestly get this side intercooler in 100mm thick and have space.

Roughly slopped the front back and grill on, barely see the intercooler walking around it.

Started it up and drove it outside the workshop and let the motor run for a while.

Gave it a couple of revs and none of the silicon bends popped off (they have no clamps currently), so that’s a small victory.
Next up it’s time to add the mounts for the intercooler to bolt it to the chassis and to get some clamps on the bends.
Till next time!

Legnum – Intercooler Upgrade – Part 5

Time to punch on.

After marking where the pipe intersects, it was time to get the grinder out to trim it.

Roughly trimmed with the grinder, it was then cleaned up with a file.

Fitted back onto the intercooler, ready for welding.

Horrible welds, but they will do the thing.

The fitment is acceptable.

And the silicon bend fits on with minimal issues.

Looks like it should do okay.

Unfortunately the local AutoOne didn’t have a 135 silicon bend in stock, so I have to wait for one to be ordered in before I can start on the next side.
Until next time.

Legnum – Intercooler Upgrade – Part 4

With the Legnum running, time to get back onto making this intercooler work.

The plan is to weld up these old inlet holes.

So out came the 2.5″ hole saw and some 4mm aluminium plate.

Two of these were cut out.

Plonked on and ready for welding.

Wow. I am rusty as feck with the TIG. I dipped a few times and a couple of times I had a gust of wind come into the workshop and blow the argon off the weld causing instant porosity… But what ever, I’m no Instahoe welder.

Intercooler fitted back in so I can begin working on the inlet pipes.

I ended up buying a 300mm straight 2.5″ intercooler pipe which comes a bead on both ends. I will cut each end off to use as an inlet/outlet on the intercooler core.

Working out roughly where the holesaw will have to go into the intercooler end tank.

A pilot hole drilled, ready to guide the hole saw.

Eye balling the correct angle.

This looks like complete ass with the piece removed.

However the pipe fits pretty nicely! The silicon will go on nicely.

The inlet has now been marked and oriented, it will soon be removed and have the excess trimmed.

Once it is trimmed, it can be welded.

Pretty good flow into the core, with a less steep inlet angle compared to the original tank design on this intercooler.

I ran out of time to keep working on this, so I’ll be back at it another day.

Till next time.

Legnum Major Service – Part 19

Buttoning up more stuff on the Legnum

The exhaust was refitted with gaskets and goop.

Radiator reinstalled with two brand new radiator hoses

I forgot to take the remaining photos of adding the rest of the intake box back on and putting the battery back in.
All the fluids were added and a temporary pipe was added to fill in for the intercooler so I could start the car for the first time.

And it runs!