JLee's 1991 Toyota MR2 Turbo build thread

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skyking

Lifer
Nov 21, 2001
22,369
5,330
146
Cool beans. I have a new turbo for the truck that will need clocking for sure.
 

jlee

Lifer
Sep 12, 2001
48,517
223
106
did you save money doing all this yourself or would it have been easier/cheaper to buy aftermarket parts and install it yourself?

Almost everything is either aftermarket or OEM Toyota.

Turbo pulled from the car:


Rather than making a new oil drain, JCH13 noticed that one I already had would work if we swapped the elbow out of an old flange into the one on the turbo:


Bingo.


This is the o2 sensor that came with the turbo/downpipe. Dear lord, what the fuck...


Braided line with t-fitting in the head (with stock and aftermarket oil pressure sensors installed) - I just need to figure out where I want to mount it:
 
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jlee

Lifer
Sep 12, 2001
48,517
223
106
Intercooler is in. O2 sensor wiring has been repaired properly. The big bracket thingy that bolts to the head is back in. My pile of parts is dwindling - I need to hook up the rest of the intercooler piping and put the intake back in!
 

bonky

Junior Member
Apr 16, 2011
11
0
0
man on a mission - i envy your progress... it's gettin me excited to get out to the garage and work on my own rigs.

thanks for the inspiration jlee and JCH13. keep up the nice work.
 

jlee

Lifer
Sep 12, 2001
48,517
223
106
aaand I am short four Breeze clamps! I forgot that I scrounged some of 'em when I did the turbo/intercooler swap on the scooby...dammit. I suppose I could get t-bolts from Autozone or something, but I'm not a fan of them. I'll check the semi-truck place in the morning and see if they have any.

I do need to adjust the turbo slightly, which SUCKS because I've already hooked up the oil lines. Ahwell, it's only time, right?

Edit: Oh, those wires a couple posts earlier? Yeah, they were just twisted together under the tape...brilliant, aye?
 

alkemyst

No Lifer
Feb 13, 2001
83,769
19
81
aaand I am short four Breeze clamps! I forgot that I scrounged some of 'em when I did the turbo/intercooler swap on the scooby...dammit. I suppose I could get t-bolts from Autozone or something, but I'm not a fan of them. I'll check the semi-truck place in the morning and see if they have any.

I do need to adjust the turbo slightly, which SUCKS because I've already hooked up the oil lines. Ahwell, it's only time, right?

Edit: Oh, those wires a couple posts earlier? Yeah, they were just twisted together under the tape...brilliant, aye?

T-bolts are more than adequate for most of the turbo applications out there. I don't get those that will hunt hours for a $100 turbo and then spend about that in clamps and couplers getting the best (not saying you have a $100 turbo).
 

exdeath

Lifer
Jan 29, 2004
13,679
10
81
I encountered a car with fuel pumps connected that way to the fuel pump controller; twisted together and wrapped in tape. No solder, no crimp connectors, nothing.
 

jlee

Lifer
Sep 12, 2001
48,517
223
106
T-bolts are more than adequate for most of the turbo applications out there. I don't get those that will hunt hours for a $100 turbo and then spend about that in clamps and couplers getting the best (not saying you have a $100 turbo).

T-bolts squash pipes if they're overtightened & I really like the CT clamps. All season tires are "adequate" too, but that doesn't mean I shouldn't buy Star Specs. And no, I don't have a $100 turbo. Hell, you could buy several eBay turbos for what my boost controller retails for.

Started reassembly:




I found a rather nasty intake pipe:


Eww.


Just a little better:


Looking like an engine now!



Aaaand voila: http://www.youtube.com/watch?v=GIc-ngvXM84

The oil pressure gauge reads 0psi but I have no idiot light, so I'm quite sure I have pressure..plus it would make all sorts of interesting noises. It is running a little funny, but I also swapped to an unknown-condition o2 sensor so that may have something to do with it? If not that, maybe the 4mo-old 1/8th tank of gas has a bit of condensation in it...I was planning on dropping the tank so I ran it pretty low. I think I'll put some fresh gas in it and burn a tank before I drop it out - want to make sure it's running normally before I tear into anything else.
 

sjwaste

Diamond Member
Aug 2, 2000
8,757
12
81
Does the 3S use a distributor or individual coils? If the latter, the cam position sensor is always just slightly off when you reassemble the top end - pull out the timing light and see if that's the cause of it running funny. I really doubt it's the gas - I just had a tank sit for a year and the car runs fine after adding a can of seafoam.

Just noticed the video. That sounds like an idle miss. Would suggest checking timing, all ignition connections, electrical connections to the injectors, etc. I don't think a bad O2 sensor would do that to you. Hell, I've idled with it completely disconnected and it just ran very rich.

Congrats on getting it all back together. That is going to be one great ride.
 
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exdeath

Lifer
Jan 29, 2004
13,679
10
81
Does the 3S use a distributor or individual coils? If the latter, the cam position sensor is always just slightly off when you reassemble the top end - pull out the timing light and see if that's the cause of it running funny. I really doubt it's the gas - I just had a tank sit for a year and the car runs fine after adding a can of seafoam.

Only 4th gen ST215 engines have COP and have never been used in a US car. All others have distributors. I'd start with the basics: start pulling plug wires one by one while it's running. If all cause a drop out and are working properly, then disable ECU advance with a jumper on the diagnostic port and set 10 deg base timing by rotating the distributor.

Are these your new injectors and do you have the new ROM loaded for those injectors? Any change to injectors or MAF without a ROM update is going to run like crap if at all.

An O2 sensor isn't going to have any effect on cold start in open loop.
 
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jlee

Lifer
Sep 12, 2001
48,517
223
106
Does the 3S use a distributor or individual coils? If the latter, the cam position sensor is always just slightly off when you reassemble the top end - pull out the timing light and see if that's the cause of it running funny. I really doubt it's the gas - I just had a tank sit for a year and the car runs fine after adding a can of seafoam.

Just noticed the video. That sounds like an idle miss. Would suggest checking timing, all ignition connections, electrical connections to the injectors, etc. I don't think a bad O2 sensor would do that to you. Hell, I've idled with it completely disconnected and it just ran very rich.

Congrats on getting it all back together. That is going to be one great ride.

I didn't take the top end apart - just pulled the valve cover. I'll check all the plug wires in case one of them is loose. There's a minimal amount of fuel in the tank - I have a feeling there's a bit of condensation in there.
 

sjwaste

Diamond Member
Aug 2, 2000
8,757
12
81
I didn't take the top end apart - just pulled the valve cover. I'll check all the plug wires in case one of them is loose. There's a minimal amount of fuel in the tank - I have a feeling there's a bit of condensation in there.

Oh, check the distributor/coil ground too.

Dump in a can of seafoam if you have it. You'll know if its condensation. It just sounds too regular a miss to be the fuel, though. Did you remember to put all 4 plugs back in? I know what an engine sounds like with one missing!
 

sjwaste

Diamond Member
Aug 2, 2000
8,757
12
81
Only 4th gen ST215 engines have COP and have never been used in a US car. All others have distributors.

Ah, did not know that. I have a 7M of the same year and it's a waste spark setup - 3 dual coil packs. Not COP though, still uses wires from the coil to the plug. I thought the 3S-GTE from the same year might've used the same electronics with one less pack.
 

exdeath

Lifer
Jan 29, 2004
13,679
10
81
Ah, did not know that. I have a 7M of the same year and it's a waste spark setup - 3 dual coil packs. Not COP though, still uses wires from the coil to the plug. I thought the 3S-GTE from the same year might've used the same electronics with one less pack.

Nope, one coil with a cap and rotor driven by the intake cam Old skool.
 
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jlee

Lifer
Sep 12, 2001
48,517
223
106
Oh, check the distributor/coil ground too.

Dump in a can of seafoam if you have it. You'll know if its condensation. It just sounds too regular a miss to be the fuel, though. Did you remember to put all 4 plugs back in? I know what an engine sounds like with one missing!

Didn't pull the plugs either; just the wires. I'll double check those tomorrow.

Only 4th gen ST215 engines have COP and have never been used in a US car. All others have distributors. I'd start with the basics: start pulling plug wires one by one while it's running. If all cause a drop out and are working properly, then disable ECU advance with a jumper on the diagnostic port and set 10 deg base timing by rotating the distributor.

Are these your new injectors and do you have the new ROM loaded for those injectors? Any change to injectors or MAF without a ROM update is going to run like crap if at all.

An O2 sensor isn't going to have any effect on cold start in open loop.

Nope, fuel system is untouched - have not sent the ROM tune out yet.
 

exdeath

Lifer
Jan 29, 2004
13,679
10
81
Didn't pull the plugs either; just the wires. I'll double check those tomorrow.

Cap goes 1-3-4-2 CCW not 1-2-3-4 CW

It's very easy to follow the cap CW and get 1-2 right and get 3-4 swapped and running on two cyls when you're not thinking about it, ask me how I know :hmm: How to make your 5S/3S sound like a Harley.
 
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jlee

Lifer
Sep 12, 2001
48,517
223
106
Cap goes 1-3-4-2 CCW not 1-2-3-4 CW

It's very easy to follow the cap CW and get 1-2 right and get 3-4 swapped and running on two cyls when you're not thinking about it, ask me how I know :hmm: How to make your 5S/3S sound like a Harley.

hahah yeah, I only pulled them off the dizzy to clean them, and I did that one at a time...and I labeled the other wires as I took them out, so I wouldn't screw up. The wires should be in the right spot..I'll make sure they're all tight, and also put fresh gas in.
 

JCH13

Diamond Member
Sep 14, 2010
4,981
66
91
You didn't use fuel stabilizer did you?

I'd bet bad gas. I have had that stumbling idle happen to vehicles before when they were running on old gas without stabilizer.
 

SuperSix

Elite Member
Oct 9, 1999
9,872
2
0
It's a misfire - not bad gas. It's too rhythmic to be bad gas.

Possibilities:
Cracked plug wire/boot, incorrect firing order, moisture in cap, carbon traces shorting in cap/plug boot, valve not opening, timing way off, etc.

Probably something simple - I've missed some REALLY basic shit at the end of a huge project.
 

jlee

Lifer
Sep 12, 2001
48,517
223
106
I pushed all the wires down and it runs great now. Unfortunately, I have an oil leak. Gah.

At first I thought it was the turbo oil feed...but now I think it might be the oil cooler. I didn't have new o-rings when I reassembled it after doing the coolant hoses - wondering if they would be leaking..?
 

SuperSix

Elite Member
Oct 9, 1999
9,872
2
0
I pushed all the wires down and it runs great now. Unfortunately, I have an oil leak. Gah.

At first I thought it was the turbo oil feed...but now I think it might be the oil cooler. I didn't have new o-rings when I reassembled it after doing the coolant hoses - wondering if they would be leaking..?


I tore an oring reinstalling an oil cooler line - dripped a little, not too bad. Bought an oring asst from a local parts store - worked fine.

Can't see where it's coming from?
 

jlee

Lifer
Sep 12, 2001
48,517
223
106
We think it's from the oil cooler somewhere - going to re-torque the main bolt with a calibrated torque wrench and see if that solves the problem. If not, I'll have to pull it all apart again, which is gonna suck...

I had an appointment to get the car inspected tomorrow afternoon, but somehow I doubt it'll be ready by then!
 

alkemyst

No Lifer
Feb 13, 2001
83,769
19
81
Anytime you break something apart I always replace all the seals and like...even if they are 'reusable'.

I am not breaking things down enough that replacing them matters (yes a manufacturing error is always possible unless you inspect them prior).
 
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