Setting up a D2 inlet manifold on a D1 engine

**miles** · 12th August 2010, 04:21 PM

I got in touch with the guy I bought the thor manifold from and also bought the D2 fuel rail as well.
I will modify the ends to suit fitting the D1 fuel pressure regulator and fuel return to the tank.
My disco engine has a Haltec E6 management installed and I don't have an Air flow meter, But I have a couple vacuum gismos the D1 plenum. All in all I have 6 vacuum take off.
Hooking up these I don't see a problem. May have to drill out a couple of bungs/indents in the thor and tap in some theads and brass take offs.

Now a couple of questions. Good ones for Philip A.
1. The stepper motor connection. Do you connect a vac hose(from the SM) to the brass take off in the throttle body (pointing down on the angle) and then the return hose to the brass take off immediately behind the throttle body in the plenum? I know they are different sizes.

2. The go cables. Would my task be a bit easier if I bought from a wrecker a autotrany kick down cable and a excelerator cable off a D2?

**PhilipA** · 12th August 2010, 08:19 PM

1. The stepper motor connection. Do you connect a vac hose(from the SM) to the brass take off in the throttle body (pointing down on the angle) and then the return hose to the brass take off immediately behind the throttle body in the plenum? I know they are different sizes.

The one pointing down on an angle is the connection to the inlet of the crankcase ventilation. I used this as the outlet for the crankcase ventilation from the 14CUX. The hose that comes with it can be bent around to join the T if heated up.
The big hose point half way along the manifold front pipe is the inlet for the stepper. I used it as the inlet from the stepper. I made a hose outlet on the hose that joins the throttle body to the MAF by cutting a hole in a length of silicon hose , waisting a bit of heater hose and aralditing it into the MAF hose.

The go cables. Would my task be a bit easier if I bought from a wrecker a autotrany kick down cable and a excelerator cable off a D2?

Well zat would be difficult as a D2 does not have a kickdown cable, and therein lies the biggest hassle of the lot. I made up a "relay" and then made an extension from bike brake cable.The hardest bit is making up an arm exactly the correct length to give kickdown at full throttle and making the flat sided hole to key onto the throttle shaft. A lot of drilling and filing with jeweller's files.

I just shortened my accelerator cable by cutting the outside to length and then the inner and silver soldering the original end onto the shortened cable.
regards Philip A

Tombie · 12th August 2010, 08:35 PM

These pics may help:

**miles** · 16th August 2010, 11:53 AM

Tombie2. Thanks mate for the photos. A big help.

A couple of questions though.
Photo 3. The stepper motor. That doesn't look like the old D1 type? And the second vacuum hose that drops out of the picture, where does that go too?

The picture of the cable hook ups. The second cable looks to me to be another D1 accelerator cable, obviously modified to hook up the auto and a back to front cable wheel on the throttle body, am I right? (I got one of those cable wheels, pinched it off one of my sons many Toyo turbo six engines)

The next observation. That pressure thingo hanging off the fire wall, it looks like a fuel pressure regulator. Not the one off the D1 fuel system. Have you converted over to the D2 system, using a high pressure pump?.

Last of all your thrermostat and top rad hose hook up. Did you do what PhilipA did as described in his thread and machine out the hole in the manifold to take the D1 thremo and cover?

Cheers

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Setting up a D2 inlet manifold on a D1 engine

Photos of Thor manifold by Tombie2

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