How to build a 5efte/4efte DIS

How to build a Turbo Toyota DIS "E" Series Engine Vol. 1

Introduction and Parts

This article will attempt to give you the information needed to put together a more powerful and more up to date engine build for your 91-99 Toyota Tercel or Paseo without completely breaking the bank. Only application specific tools will be listed.

You can do this build without a garage or a lift, but you can't do it without a full complement of basic automotive tools used for building and repairing engines and transmissions, so I won't list them. Also, do yourself a favor and purchase a Toyota Repair Manual and Wiring Diagram for your vehicle. This will make it easier to perform any modifications needed. This article will be as detailed as possible, but is subject to change if better or less expensive methods and or parts are found. This article will also provide high performance options that will increase the potential of this build, but we will start with the affordable. The idea is to come as close as money will allow to duplicating the performance of the extremely rare Toyota 1nzfte engine (pictured below), but in a package that works in EL and EP Toyotas.

The first thing is to decide how much horse power and torque that you need or want. Choose wisely, as this will determine your final cost. The cheapest base engine will be a 4efte. The  next best choice for higher performance would be a 2nd generation 5efe with the distributorless ignition system. Then you have your 1st generation 5efe, the 5efhe, and the 4efe. These last three engines will require you buying the most parts and will be more expensive. At a later date, a step by step install guide with pictures will be added. This article will list parts for all build options first and then detail the assembly and installation.

Basic Turbo DIS "E" Series Engine Parts List

1. 4efte complete engine/turbo/sensors, unless you are starting with a 4efte. ECU, wire harness, and transmission are not needed in a Paseo or Starlet, but are very helpful in a 91-94 Tercel equipped with the Single Over Head Camshaft 3e engine.

2. Aftermarket mild steel or cast turbo manifold and down pipe. This will save headaches later. You can get stainless steel, but sometimes the quality doesn't match the looks.

3. Aftermarket waste gate actuator. This will give you more control and protect against boost creep. Boost creep is a common limiter of the stock 4efte engine.

4. 5efe DIS complete head with camshaft sensor and coil on plug ignition units. You may want to get the entire ignition from a 95+ Tercel or 96+ Paseo from a salvage yard.

5. 5efe DIS oil pump with crankshaft sensor and crankshaft timing pulley gear. I suggest the TOGA high flow oil pump unit. Be sure to get a new timing belt and tensioner.

6. Front Mount Inter-Cooler and intake system. You will find it difficult to close your hood without it. You can maintain the Top Mount Inter-Cooler by adding a hood scoop.

7. 92-95 Honda Civic 2 row radiator (the small one) and aftermarket low profile fan to match. This will allow you to fit the turbo and still maintain air conditioning. You may need to buy bendable radiator tubing to make this install easier. Mount it to the right.

8. Piggy Back Engine Management. I suggest the AEM F/IC-6 for OBDII cars, but the Link Engine Management G4 Storm and the ever popular Greddy e-Manage (Blue or Ultimate) can also be used and are similar in price. Be sure to get all harnesses and adaptors to drive the distributor less ignition and to monitor the MAP sensor and control boost. My choice for OBDI cars is the Link Engine Management G4 Storm.

9. Custom 2.5 inch to 3 inch exhaust with a metal core catalytic converter. Your common ceramic core can melt from the added heat that comes with turbo power and may cause problems later. You can also adapt a Starlet turbo exhaust to fit.

10. Some sort of boost controller and whatever type of blow of valve that you like.

11. If using your stock transmission, you must get a clutch made for the Starlet 4efte. Typical odds and ends must also be added. This includes spark plugs one heat range colder than normal, new gaskets and seals, water pump, thermostat, coolant, high quality oil, and other small parts that you would change in a tune up or rebuild. That is the basics for parts on a 4efte DIS. If you have a 5efe DIS in your car now and want to do the 4efte DIS, you could maintain your ECU and just add a APEXI Neo and a Missing Link by Synapse for a basic, lower cost system that isn't as adjustable as a piggy back ECU.

Turbo DIS "E" Series Engine High Horsepower Parts List

The easiest and best way for your average tuner to start here is to buy two engines. You can find all the parts separately, but this is time consuming and can actually cost you more. If you plan to seriously race your car, buying as many new parts as possible is your best bet because you know that your parts aren't worn and out of spec.

Cryogenic treatment, thermal and friction coatings are all a must for a race engine. This section will first list your most affordable power options and then the more expensive options. The following is being written as if you have a 92-95 Paseo and want to do this build, but can be applied to 91-99 Tercels, 96+ Paseo, and 90+ Starlets. Just make the proper adjustments based on your starting engine and platform. Use performance based fluids for this build. Again, you will need the manual and wire diagram for your car.

"Affordable" Power Parts

1. 5efe DIS engine. A junkyard engine would probably be best because you are more likely to get all parts and sensors for a lower price. Rebuild the engine using a High Flow Oil Pump and replace any parts that are needed.

2. 4efte complete engine. These can be found from around $400-$1000 with the turbo, intercooler, and most sensors. Don't pay over $1K unless you need a transmission or want the wire harness and ecu. The wire harness and ecu are only helpful to 91-94 Tercel owners in this instance or if you want to pay less for a piggy back.

3. Forged 5efe connecting rods. Even though they are forged, cryo treatment still helps.

4. Cryo treat a set of 5efe DIS pistons. Have the pistons skirts friction coated and the piston top thermal coated. This is almost as good as plain forged pistons at a fraction of the cost. Use 4efte pistons if you are scared of "higher compression boost".

5. 0.6mm TRD or comparable Metal Head Gasket. Going thicker decreases off boost power and torque by lowering compression, but makes it "safer" to turn up boost.

6. Tubular or Cast Turbo Manifold with matching Downpipe.

7. HKS or comparable Wastegate Actuator.

8. Front Mount Intercooler with upgraded Blow Off Valve.

9. Custom 3" exhaust and 3" metal core Cat converter.

10. 255lph Fuel Pump, 330cc Fuel Injectors and a Rising Rate Fuel Pressure Regulator.

11. Custom Cold Air Intake with a AEM Dry Filter and By-Pass Valve.

12. Iridium Spark Plugs one temp range colder than stock with 8.5mm or larger Spark Plug Wires. (Remember, this is a DIS, you only need two.)

13. Piggy Back Engine Management. Any of the ones listed previously will work.

14. 92-95 Civic Radiator and fan mentioned previously.

15. Common tune up and rebuilding parts.

Ultimate Power Parts

This is all obvious stuff and doesn't require an actual list. Use Forged Pistons and Rods for starters. Use a Hybrid Toyota CT9 Turbo or a replacement like the affordable and versatile T3/T4 turbo. Replace the internal wastegate with a high quality external one and a turbo manifold/downpipe combo to accommodate the upgrade. 550cc fuel injectors with maybe a custom fuel rail and a in-line fuel pump with high performance fuel filter. A custom air intake manifold would help. Adding additional cooling like a Aqua-Mist system, alcohol injection, or a DEI CryO2 system. Nitrous Oxide can always be added, but may not be allowed on a track other than a drag strip. Up-rated axles, bushings, engine mounts, braided lines, 6 and 4 puck clutches, the list goes on. This is basically a dream list that may contain one or two parts that may be integrated into your build. Once to this level, you will probably be exceeding the worth of your car by 4 times over, but that's ok if you got it.

WARNING!!

The above article is meant as a guide and is by no means a "sure fire" way to get the results that you want. You may change parts at your liking. Part numbers were not listed as there are several types and manufacturers of each part, giving you a choice based on your budget and preference. Volume 2, the "How To Install" article, will have part numbers of any particular part or special tool used. Please use the search engine of your browser and your favorite forum to gather the information required. Also, buy the manual for your car! I can not stress this enough! Waiting on a forum for someone to post a diagram or help you isn't reliable. A proper manual will pay for itself by it's second use if you consider time spent online and/or the current cost of labor for a shop to look at your car. If you don't have the place, tools, information, experience, or knowledge to move forward from here,

PLEASE don't attempt to do so as serious damage to your vehicle or injury to yourself may occur. Seek a knowledgeable, experienced friend for help or take it to a professional if you are having trouble. There will be a "How To" in the future, but even then, don't risk it unless you have the proper tools and information and never perform heavy or dangerous work alone if you are inexperienced.

Written by Cris aka Paseo15psi/Paseo Racer

Toyota Paseo & Tercel 4efte/5efte DIS Parts List

This is more to help me keep track of the parts I used for my engine builds, but I figured I would share. You may use this as a general outline of what parts to buy. Substitute parts as budget and availability dictates. To make things easier, this list will be written as if you were starting with a 1992-1995 North American Market Paseo without an engine as it is being based on my 1992 Paseo build. I will also make notes as to what different parts I may have used on my OBDII 1996 Paseo that is getting a 4efte. Use your Repair Manual and Wiring Diagram for your car to figure out exactly how to proceed with your vehicle, as a newer OBDII car or a 4th Gen Tercel (91-94) will be different.
 
Why a DIS build? I wanted to share parts between my two Paseos, so I figured why not update my 92 Paseo to a Distributorless Ignition System and not have to worry about buying caps and rotors ever again. Plus having sensors, that know exactly where the cams and crank are, helps tremendously with tuning. My 96 will have the stock ECU, Synapse The Missing Link MAP sensor adaptor to hide boost, and a AEM Fuel/Ignition Controller piggyback setup on a 4efte with a complete 5efe DIS head and crank sensor. This car will be very basic as it's daily driven. My 92 will use the stock ECU and a Link Engine Management System G4 Storm (or something similar) to directly control the ignition conversion and fuel system. The 92 has a 5efhe block (high compression pistons and all) with a normal 5efe intake manifold and throttle body. At the time of install, the engine ran better without the ACIS intake. That was before I found out how to operate the secondary intake runner butterflys. This engine will get a 5efe DIS head with cam sensor and the 5efe DIS crank sensor and oil pump, along with all the parts from a 4efte needed to add turbo. I will also attempt to modify my own ct9 turbo to try and tune the turbo's usable power range. I want more low end power from this build as the 92 Paseo will be used mostly on Circuit Tracks and street driven on some weekends. This means that high horsepower isn't as important as throttle response and acceleration. A smooth, even power curve is the goal here.

1996 Paseo 4efte DIS Parts Check List

Toyota Starlet 4efte. Preferably the newest you can find. The newer ones are more likely to have the better ct9a turbo, but that isn't a guarantee in the slightest.

5efe DIS head, cams, cam sensor, oil pump with crank pulley gear, crank sensor, and intake manifold with throttle body (to maintain the EGR system). Hopefully you have a DIS engine to borrow
from. If not, a salvage yard is your best bet, grab the entire ignition and engine wiring including ECU to make things easier. It is otherwise difficult or very expensive to get these parts. You can convert a distributor set up over to DIS with aftermarket parts, but doing it the way I suggest is cheaper and probably easier. As for the oil pump, I am using a Toga Performance High Volume pump. Part Number OPT032C-HV from www.ImportPerformanceParts.net

5efe DIS engine rebuild kit. Get a ct9 turbo gasket and seal kit too for extra insurance. I used Toyota engine overhaul kit Part Number

04111-11160. You can also use Part Number 50136400 Gasket kit from Ajusa or just about any other kit for much cheaper. The turbo gaskets and seals from Toyota are Part Numbers 04175-11031, 04176-11020, 16347-42020.

Custom exhaust. I will be making my own, but you may choose to have a shop make it for you. I chose to use parts from Vibrant Performance. Use a metal core catalytic converter so that the increased heat from the turbo power doesn't melt your cat. A standard ceramic brick may melt after some hard use. Also, try to use a 2.5" or 3" exhaust to help the turbo make power.

Turbo manifold and downpipe. Not needed, but highly recommended. This is a piece I will order at a later date from Toy Tuning. I will order a Japspeed tubular turbo manifold and downpipe. This is a daily driver and boost will be modest, I don't need the extra strength of mild steel.

Sard Blow Off Valve charge pipe. I will be maintaining the Top Mount Inter-Cooler for a while on this car. So I will get this piece so that I can swap the stock recirculating BOV with a more reliable one from Perrin. Again, not needed, but good insurance.

Wastegate actuator upgrade. There are several out there. I went with the Toy Tuning one because of price alone,

www.ToyTuning.com for the part. HKS also offers one but it is expensive and the Toy Tuning one has been proven to work just as well. Reason for this part? Insurance against boost creep.

Air intake. Sometimes the 4efte will come without a complete intake. I have a Weapon R Secret Weapon Universal air intake that I'm going to make work. Part Number

339-111-101. May have to use a 90 degree elbow to get around the power steering and a/c compressor pumps.

MAP trickery. Check out

www.SynapseEngineering.com for Missing Link Part Number ML002. No archaic aquarium check valves here! This fixes the Air part of boosting. You could stop here if planning to stay under 9psi, but what fun is that?

Fuel and ignition control. AEM F/IC-6 or Fuel and Ignition Controller. This will allow better control over fine tuning the system and is made mostly for OBDII cars. Part Number

30-1910. Use a Synapse Fuel Pressure Regulator Part Number SC001 to gain better control.

Spark. I used TRD spark plugs Part Number

10901-SP070-22 which is one heat range colder than stock. I'm using Moroso 8.5mm wires, Part Number 45213.

Fluids. I just like to use Royal Purple whenever possible. They make every major fluid needed and it is all proven to improve power and reliability. Get some. Also will try some Z-Max.

Extra insurance. Poly engine and transmission mounts. Check Toy Tuning for these. They are cheaper and better than the TRD hard rubber ones.

Don't forget gauges for boost and such, flywheel, clutch kit, and smaller 92-95 Civic radiator with slim mount fan and custom hoses.

1992 Paseo 5efte DIS Parts Check List

Toyota Starlet 4efte and a 5efe short block. Use the 5efe block and add the 4efte turbo parts and the 5efe DIS parts. Or just start with a 5efe DIS complete engine. I recommend buying the entire 4efte so that you have most of what you need to turbo. It costs a lot more to buy it all separately. Look for the "How to" coming soon.

5efe DIS head, cams, cam sensor, oil pump with crank pulley gear, crank sensor. Hopefully you have a DIS engine to borrow from. If not, a salvage yard is your best bet, grab the entire ignition and engine wiring including ECU to make things easier. It is otherwise difficult or very expensive to get these parts. You can convert a distributor set up over to DIS with aftermarket parts, but doing it the way I suggest is cheaper and probably easier. As for the oil pump, I am using a Toga Performance High Volume pump. Part Number

OPT032C-HV from www.ImportPerformanceParts.net 5efe DIS engine rebuild kit. Get a ct9 turbo gasket and seal kit too for extra insurance. I used Toyota engine overhaul kit Part Number 04111-11160. You can also use Part Number 50136400 Gasket kit from Ajusa or just about any other kit for much cheaper. The turbo gaskets and seals from Toyota are Part Numbers 04175-11031, 04176-11020, 16347-42020.

Custom exhaust. I will be making my own, but you may choose to have a shop make it for you. I chose to use parts from Vibrant Performance. Use a metal core catalytic converter so that the increased heat from the turbo power doesn't melt your cat. A standard ceramic brick may melt after some hard use. I'm going to use a 3" exhaust here.

Turbo manifold and downpipe. On this car I will be using the Toy Tuning mild steel ceramic coated turbo manifold along with the Zep Racing downpipe. More displacement means stronger parts to handle the power.

Front Mount Inter-Cooler. This will be some sort of custom unit using universal pieces.
 
Wastegate actuator upgrade.
www.ToyTuning.com for the Toy Tuning unit, or try HKS. This will allow me to turn the boost up higher and still be safe.

Air intake. Sometimes the 4efte will come without a complete intake. I have a Weapon R Secret Weapon Universal air intake that I'm going to make work. Part Number 339-111-101. I will also delete the coolant lines in the throttle body. Don't do this on a daily driver if you live anywhere that has cold weather! I will also use throttle body and intake manifold spacers.

Fuel and ignition. Start with a Link Engine Management Systems G4 Storm to control everything, you can use a e-Manage if you like. 550cc fuel injectors, 5gal fuel cell with a racing fuel pump and fuel filter (you can use your stock tank with a 255lph fuel pump and a high flow inline filter replacing the stock one), a Synapse Fuel Pressure Regulator Part Number SC001, TRD spark plugs Part Number 10901-SP070-22 which is one heat range colder than stock, Moroso 8.5mm wires, Part Number 45213. May convert to AEM individual coils later.

Blow Off Valve. I'm going to use a Steed Speed inline BOV. I sell them and I want to use one. Use any BOV you like.

CryO2 system from DEI to cool the intake charge, fuel rail, and intercooler. This is a maybe because it may not be legal on a circuit track. This may be street only. If so, I may use the Speed Max intercooler with the cooling element inside the intercooler.

Throttle rotor upgrade. This is to increase throttle response.www.RHDJapan.com has these.

Fluids. I just like to use Royal Purple whenever possible. They make every major fluid needed and it is all proven to improve power and reliability. Get some. Also will add Z-Max.

Extra insurance. Poly engine and transmission mounts. Check Toy Tuning for these. They are cheaper and better than the TRD ones. Also braided lines and T-Bolt hose clamps. Pick up a AEM air intake by pass valve if you use a cold air intake. Try a pre filter for the throttle body.

Don't forget gauges for boost and such, flywheel, clutch kit, and smaller 92-95 Civic radiator with slim mount fan and custom hoses. TRD thermostat, radiator cap, dress up items, and anything else to help performance. Search www.TercelOnline.com for TRD part numbers.

Modify the ct9 with a ct12b exhaust shaft and turbine. Baffled oil pan. Again, Toy Tuning. Forged rods and pistons. Check my engine build PDF article for options here. I personally will only use forged rods and use 5efe DIS pistons cryo treated, thermal coated, and friction coated. Check www.Race-eng.com for the forged items for a 5efe.

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