JLee's 1991 Toyota MR2 Turbo build thread

[jlee]

There is now a part 2!

We've come a long way.

Current list of things to do as of August 2016:

Install new shift boot/surround
Install new steering wheel clamshell trim
Install new AC idler pulley assembly
Test / recharge AC system
Repair climate control slider
Replace body clips in door panels
Install new grommet in frunk for the HID conversion wiring
Permanently mount HID conversion parts
Fix off-center ignition switch (bent steering column...?)
Locate/fix exhaust leak
Respray front end (rock chips)
Respray roof with t-top seals removed, install new ones
Install fog lights (preferably OEM converted to LED)
Weld IAC and PCV bungs to intake tube, reroute IAC and PCV to intake
Replace/rebuild steering rack, maybe replace motor assembly (P/S light is always on)
Determine what wheels I'm going to get so I can run a 275 rear tire

Current dyno sheet as of April 2016:

Don't be lazy - read the thread. Now with forged rebuilt motor, etc.

Updated with video 8/27/2012

Updated with dyno sheets 11/5/2011
LINK HERE - post #471

Mod list as of Spring 2015
Rebuilt 3SGTE
Gen3 3SGTE cams
Cometic MLS head gasket
ARP head studs
Wiseco 86.5mm forged pistons
Stock rods
OEM Toyota bearings
Clutchmasters FX500 6 puck unsprung clutch
ATS Racing GT3071 kit with 38mm Tial wastegate (external dump)
3" ATS Racing downpipe
3" Berk exhaust
DIY intake (3" aluminum pipe with cone filter)
ECU Master EMU standalone ECU with integrated wideband and boost controller
CRW axle cages


Revamped list 08/27/2012. So much new stuff.
540cc injectors Replaced with SARD 800cc injectors Replaced with ATS Racing top feed 1200cc injectors
Walbro 255lph fuel pump
ATS Racing fuel pressure regulator
ATS Racing bored fuel rail Replaced with ATS Racing top feed fuel rail
TD05 20G turbocharger Replaced with ATS Racing GT3071 ball bearing turbocharger kit
3" ATS Racing downpipe
38mm Tial wastegate
EMS Powered oil pressure gauge (goes in stock boost gauge location)
Innovate LC1 wideband controller with gauge Replaced with AEM UEGO wideband Replaced with ECU Master EMU's integrated wideband controller
Greddy Profec B Spec II electronic boost controller Boost now controlled by MegaSquirt Plug and Play ECU ECU Master EMU







Since it was a balmy 45° today, I started disassembly.

Jacked up on stands to remove exhaust:

Jackstands removed, exhaust gone, ready to drop:

Engine bay:

Cross brace and side panels removed:

Removing stuff:

Stock intercooler fan is definitely going away (next to SPAL):

Progress! Intake and intercooler stuff is gone:

Then I remembered that I forgot to eat anything today. Oops.

More later, whenever I get to it.

 

[JCH13]

Yay for wheel chalks. And yay for the straight dump pipe you're going to run :awe:

Too bad the rest of this week will be high of low 20s :thumbsdown:

 

[Harrod]

I've always loved the 2nd generation mr2's, my uncle had a 1st gen and was always talking about how he would have loved to have the 2nd gen car.

 

[exdeath]

Fix that leak while you're in there. Looks like valve cover or distributor o ring leaking and dripping down the transmission. Wet engine/trans underside, shame on you

That distributor o ring is the bane of all Toyota 4 cyl owners.

 

[jlee]

Fix that leak while you're in there. Looks like valve cover or distributor o ring leaking and dripping down the transmission. Wet engine/trans underside, shame on you

That distributor o ring is the bane of all Toyota 4 cyl owners.

I'm probably going to do timing belt / water pump while I'm in there..might as well replace the distributor seals and valve cover gasket too. IIRC there's oil on the driver's side of the head, so it may be the valve cover.

 

[HarryLui]

What's your hp goal?

 

[jlee]

What's your hp goal?

300-320rwhp on pump gas.

 

[skyking]

300-320rwhp on pump gas.

Nice number, about what I'm looking for with my truck

 

[PlasmaBomb]

300-320rwhp on pump gas.

Nice. Throw something over the intake to prevent crap getting in there...
(you probably already did though).

Nice number, about what I'm looking for with my truck

Your truck probably weighs a damn sight more...

 

[punjabiplaya]

nice thread, get some work done you lazy bum, you have all those parts sitting around and cold weather is no excuse.

I'd like to make 320 too, although I am broke so that's not going to happen for awhile.

 

[skyking]

Nice. Throw something over the intake to prevent crap getting in there...
(you probably already did though).



Your truck probably weighs a damn sight more...

Really?
I bet the 10,000 pound trailer it tows does too

 

[Toastedlightly]

So how much boost are you looking to run? What sort of spool up?

 

[Zenmervolt]

Nice number, about what I'm looking for with my truck

I'm betting the torque number on your truck will be a wee bit higher since you're redlining at what, 3,500-4,000 RPM?

ZV

 

[jlee]

nice thread, get some work done you lazy bum, you have all those parts sitting around and cold weather is no excuse.

I'd like to make 320 too, although I am broke so that's not going to happen for awhile.

What do you think I'm doing?

So how much boost are you looking to run? What sort of spool up?

Probably 17psi, should be full boost by 3400rpm or so.

 

[exdeath]

 

[punjabiplaya]

I wish it did.

 

[jlee]

Well, I got as much done as I wanted..which is a huge plus, considering I can't do a whole lot now until I get JCH13 to weld my dump tube.

I invented my own coolant catch system, since I didn't want to dump it all on my floor (or all over the engine and hope it went into a drain pan):

I later realized that the bag leaked....ooooops.

See that coolant hose in the above picture? It refused to come off. Eventually, I came up with a solution:

FINALLY! After hours of cursing, and going back and forth from under and over the car (requiring jack/stands setup every time), I did it.

I've never had it apart this far before - something is definitely leaking...guessing the valve cover gasket, if not more:

The pile:

Just as I was wrapping up, I heard someone's futile attempts to make it up the hill by my garage. A few minutes later, the trusty Forester pulled the poor little Scion up the hill...first save of the season! No pics, unfortunately. :/

 

[exdeath]

Channel locks will take care of stubborn hoses every time

 

[jlee]

Channel locks will take care of stubborn hoses every time

I couldn't move the clamp away from the outside edge of the pipe - I think the hose expanded or something...should replace it anyway.

 

[Aikouka]

Looks nice (if it was only black! )... keep us up to date!

I've always loved the 2nd generation mr2's, my uncle had a 1st gen and was always talking about how he would have loved to have the 2nd gen car.

I've always poked around at the idea of doing SCCA and a 2nd generation MR2 Turbo is the car I'd like to use if I ever decide to go through with it .

 

[skyking]

Nice pics man.

 

[jlee]

Looks nice (if it was only black! )... keep us up to date!



I've always poked around at the idea of doing SCCA and a 2nd generation MR2 Turbo is the car I'd like to use if I ever decide to go through with it .

It used to be black..I like the orange.

 

[BurnItDwn]

My little brother is gonna be jealous as hell, he drives around in an 05 mr2 spyder.... but he's got no money and no garage to put in a turbo ... hehehe

 

[jlee]

My little brother is gonna be jealous as hell, he drives around in an 05 mr2 spyder.... but he's got no money and no garage to put in a turbo ... hehehe

2ZZ swap! :awe:

 

[Apex]

Nice, it's going to be fast.