Gary's Track Day/Fast Road Weekend Car 1zz Turbo.. Now Built 2zz Turbo with E153

[thetyrant]

Awesome work well done and car looks superb, wish i had held out for a sable!

Dont be tempted to turn up the boost as the rods on the 1zz are very thin/weak,  im told by a reputable source that 200-210 is safe limit and while some people do run higher its a big gamble and for track better to run a little less and keep it reliable, also with turbo ideally you want to try and bring the boost in gradually if your controller allows rather than a big dollop low down as this is what snaps rods, one of reasons i was thinking of rotrex as boost builds with revs so easier on rods, but think cost wise a normal turbo like you have is much cheaper way of doing it.

Look forward to updates

Ian

[Gaz2405]

I'm happy just running waste gate pressure for the minute (7psi), but may look into a digital controller further down the line.

The TD04 15T, seems to bring in the power quite smooth for the time being....

[Gaz2405]

Had an evening playing tonight, went to change the injectors out for some 630's I'd bought but after debating with my inner self it didn't looks like they would fit. Tiny bit wider and shorter, so I bottled it tonight and juts put the 2zz ones I had in laying around.



Adjusted the injector settings and off I went for a spin,  seemed ok but was hesitating under load.

A quick check of the settings again and I'd changed the lag settings but not the duty %, so it was running super rich.

Changed %  in setting 5 and straight away it was idling better and pulled smooth again.

Coming back though I noticed what sounded and felt like a flat osr tyre, the rumble you get. Got out to check and nothing....

Any ideas? Drive shaft perhaps?

[1979scotte]

Respect for the road tuning I'd still like to see it go on a RR.
Not sure how you find enough room to get it done both my modified 2s are way too fast.

@thetyrant pm the name of the member that told you 210 because first I've heard of it. Club generally recommends staying below 240 ftlb torque for gearbox longevity.

@spit has reliably ran more I believe. Certainly more bhp.

[thetyrant]

@thetyrant pm the name of the member that told you 210 because first I've heard of it. Club generally recommends staying below 240 ftlb torque for gearbox longevity.

@spit has reliably ran more I believe. Certainly more bhp.

It was the guys at Se7en motorsports who should know what they are talking about .. the did say plenty have ran more but usually not for any length of time and certainly not on track, occasional blast on road/drag/dyno will put lot less stress on rods compared to constant abuse on track soon which soon finds the limits, each to there own but I prefer to be safe than throw out a rod and think 200hp is enough for MR2 anyhows

Always interested to see other pushing the limits but for my cars I play it safe

Looking forward to what this setup makes if it goes on dyno

[Gaz2405]

If anything the road tuning and mapping (I find) is very similar to complicated estimates at work and shuffling numbers around to try and make things work!

I'm out in the country with some very long uninterrupted roads, I've got my mapping road sorted with two big pubs at either end of it. Perfecting for parking up and seeing how the changes have affected the tune.

Plan is to road tune it for a while, until it seems perfect. Then book in for a mapping session to see what it makes on my map and then to see how many mistakes I've made in it once a real tuner gets hold if it!

[1979scotte]

@thetyrant pm the name of the member that told you 210 because first I've heard of it. Club generally recommends staying below 240 ftlb torque for gearbox longevity.

@spit has reliably ran more I believe. Certainly more bhp.

It was the guys at Se7en motorsports who should know what they are talking about .. the did say plenty have ran more but usually not for any length of time and certainly not on track, occasional blast on road/drag/dyno will put lot less stress on rods compared to constant abuse on track soon which soon finds the limits, each to there own but I prefer to be safe than throw out a rod and think 200hp is enough for MR2 anyhows

Always interested to see other pushing the limits but for my cars I play it safe

Looking forward to what this setup makes if it goes on dyno

We will agree to differ then.
Both on the limits of the rods and how much power an MR2 needs.

[Gaz2405]

Just spent the last couple of hours out mapping and logging.

Wanted to bring my AFR's in a little leaner, as I'd been running it rich for fear of det.

Once I'd got my AFR'S to where I was a little happier with them and got my knock max knock levels down under 20 I started to add some timing to the upper rev range, say from 3k onwards around the load cells most used when at WOT.

The car is now running much better and power delivery is much smoother now.

Air intake temps maxed at 45ish so I know the charge cooler is doing its stuff (thanks for being persistent about one Scotte)

Although just before I took the car out of the garage, I dropped my track pump on the front bonnet, major gouge and dent right above the badge in the middle, what a bell end!

So I'm now on the look out for another sable bonnet.

Spoke to my brother inlaw about the clutch, its going to go in for one in the next couple of weeks.

Has anyone used the exedy clutch from the 2zz supercharged corolla's before?

 

[1979scotte]

Just spent the last couple of hours out mapping and logging.

Wanted to bring my AFR's in a little leaner, as I'd been running it rich for fear of det.

Once I'd got my AFR'S to where I was a little happier with them and got my knock max knock levels down under 20 I started to add some timing to the upper rev range, say from 3k onwards around the load cells most used when at WOT.

The car is now running much better and power delivery is much smoother now.

Air intake temps maxed at 45ish so I know the charge cooler is doing its stuff (thanks for being persistent about one Scotte)

Although just before I took the car out of the garage, I dropped my track pump on the front bonnet, major gouge and dent right above the badge in the middle, what a bell end!

So I'm now on the look out for another sable bonnet.

Spoke to my brother inlaw about the clutch, its going to go in for one in the next couple of weeks.

Has anyone used the exedy clutch from the 2zz supercharged corolla's before?

 

@s12vea used the stock corrolla compressor clutch I believe to.good effect.

[s12vea]

Just spent the last couple of hours out mapping and logging.

Wanted to bring my AFR's in a little leaner, as I'd been running it rich for fear of det.

Once I'd got my AFR'S to where I was a little happier with them and got my knock max knock levels down under 20 I started to add some timing to the upper rev range, say from 3k onwards around the load cells most used when at WOT.

The car is now running much better and power delivery is much smoother now.

Air intake temps maxed at 45ish so I know the charge cooler is doing its stuff (thanks for being persistent about one Scotte)

Although just before I took the car out of the garage, I dropped my track pump on the front bonnet, major gouge and dent right above the badge in the middle, what a bell end!

So I'm now on the look out for another sable bonnet.

Spoke to my brother inlaw about the clutch, its going to go in for one in the next couple of weeks.

Has anyone used the exedy clutch from the 2zz supercharged corolla's before?

 

@s12vea used the stock corrolla compressor clutch I believe to.good effect.

I used that on my tte turbo and had not issues.

Roughly 200bhp / 210 ft Ib

Stock feel as well which was nice

[Gaz2405]

Been away in the Alps for a week or so, so progress has slowed down a little.

Back on it today, with heat wrap around the manifold and DIY down pipe.






Also took out the tray from underneath the engine lid bonnet to try and help with some cooling. (The car is garaged and won't be driven in rain)

Exedy Clutch has also arrived so I'll try and get that fitted in the next week or two.





Also some pictures of my error dropping something on the hood!





I've also got an issue where I seem to be pressurising the fuel tank with boost,I've done the same Carbon canister delete as Lee and the other, but thing I'll just bin off the solenoid all together and run a breather pipe into the wheel arch or similar. (any links to any guides/posts on this?)




Near future plans are to:

Fit new clutch.

Fit 630cc Injectors.

Proper mapping session.

Fit braided brake hoses and refresh discs and pads all round.

Get some Track Tyres Nankang NS-2R or similar. 195/50/15 at front and 215/40/16 at rear. (Although struggling with this size for availability) 225/45r16 looking more promising.

Order up some new Braces, as the ones from Megillian aren't going to materialise as I've claimed through paypal.

The finally a track day towards the end of August hopefully. Most likely Blyton as it nice and close.

[1979scotte]

I wouldn't bother with the big tyres you won't need them.
I've got 250 ftlb @ the wheels on pfl 205 rear AD08R and its fine in the dry.

[Gaz2405]

I wouldn't bother with the big tyres you won't need them.
I've got 250 ftlb @ the wheels on pfl 205 rear AD08R and its fine in the dry.

Ahh Great so FL stock sizes best?

Read loads on the forum about going up a size.....hhmm

[1979scotte]

I wouldn't bother with the big tyres you won't need them.
I've got 250 ftlb @ the wheels on pfl 205 rear AD08R and its fine in the dry.

Ahh Great so FL stock sizes best?

Read loads on the forum about going up a size.....hhmm

I like small tyres.
I've had as big as 205 F 215 R and I didn't like it.
I like 185 205 the best on PFL wheels.
Everyone is different.
I'm just saying that my car has 175 ftlb of torque at 2500rpm and maxes out at 257 all at the wheels and I haven't found it a handful on public roads in the dry.
The wet is another matter.
Also my Rotrex doesn't suddenly create torque spikes like turbos can.

Chris GB had a built 2gr that ran well North of 300 bhp and he ran stockish size R888.

[Gaz2405]

Hmm will have to give it some thought, thanks for the insight.

May wait until its mapped fully before making the decision on tyres after some "spirited" driving.

[1979scotte]

Hmm will have to give it some thought, thanks for the insight.

May wait until its mapped fully before making the decision on tyres after some "spirited" driving.

The suck it and see method is a favourite of mine also.

[Gaz2405]

Quick hour or so out tonight mapping.

Playing trial and error with fuelling and ignition.

Finally feel like I'm getting to the finer part of the tune now.

Had some guys come over for a chat on motorbikes who'd seen me doing a few pulls (it's a popular road for spirited driving and also on a slight gradient so great for putting an engine under load) who were impressed and hadn't realised what a pocket rocket these cars could be.

Below is some info from another thread where I'd thought about getting it mapped by a pro but I think I've convinced myself otherwise....



I did look at Co Pilot and have a copy ready to play with. But thought I'd first get used to the standard software in FC Edit.

I have wideband connected and after some trial and error and scrolling old forum posts now have it reading the same on both the log and the gauge.

I've been logging quite a few miles, maybe a hundred or so, I tend to do short runs/pulls and check and amend the map at the side of the road.

I've got my knock levels to where i want them (max under 25).

It's now a case of bring out some fuelling to get towards an AFR across the board I'm happy with (circa 12-12.5 wot) and also change the 2zz injectors out to the 630's I've got as I'm over 90% duty over 4.5k.

Timing has been advanced quite a bit compared to the base map I used, it looked very conservative.

Re:vvti map, I've ran a couple of different base maps on this differing around 10 degs in total, but in all honesty could tell the difference on the road.

I think I'll stick with my original plan and continue to map it myself. Take it for a power run at a rolling road to see what the curve is like and go from there.

Worst case it'll either blow up or I'll have to spend a few hundred on a mapping session.

[Gaz2405]

Home from work an hour early today, so got straight to it.

Car is booked for its clutch this Saturday, so wanted to get a few bits sorted before hand.

Namely fitting the 630cc injectors and changing the plugs for some a grade cooler.

Plugs were done in 5 mins.

Injectors were another storey.... 😂

Now I'd messed up when buying them as the connectors needed an adaptor.

However, on closer inspection the top of the injectoe body was slightly wider than the 2zz injectors.

So first try was to put another o ring on top and space out the clamp spacer.

All fitted, quick test prime of the fuel rail......

Pissing out everywhere!

Back to the drawing board then.

Now being a selectively tight Yorkshire man/not been arsed to order some more, I took the brand new injectors to the bench grinder with the fine stone on.... 😂


First one done, nice tight fit still with two o rings but the injector sat 'fully home' in the rail.

Sod I thought I'll do the rest, worst case they still leak and I'll need to buy some more.

All done and fitted, injectors scaled down on the Apexi pfc....(left the lag settings the same as they're not 10year old injectors that need to extra time to open)

Boom started first time, no leaks.

Good old bodge it and scarper!

Now waiting for the laptop to charge to go out and check afr's and see what duty they're running at.
Few!

[Gaz2405]

Success!

No more slow blink cel light indicating maxed out injectors.

Pulls all the way to the limiter now.

Max duty sat at about 55%.

Cant wait for the clutch fitting now, to see what it can really do.

[1979scotte]

Success!
Hurrah!

[Gaz2405]

Ended up having to change the inj lag slightly, as the idle had started to hunt a little more.

A little trial and error and I seem to have it where it should be.

[shnazzle]

Ended up having to change the inj lag slightly, as the idle had started to hunt a little more.

A little trial and error and I seem to have it where it should be.

These settings are quite key to any corrective algorithms you have, so make sure they're spot on before you try to compensate using correction tables.

[Gaz2405]

Ended up having to change the inj lag slightly, as the idle had started to hunt a little more.

A little trial and error and I seem to have it where it should be.

These settings are quite key to any corrective algorithms you have, so make sure they're spot on before you try to compensate using correction tables.

Yeah trying to find any reliable data online is a little tricky.

I've saved down all the settings and reinitialed the Pfc then let it do its thing with the self learn idle again and we appear to be spot on.

Rest of the map is 'fine' (at least it seems to be).

I was just having an issue on non load idle with the larger Injectors.

[Gaz2405]

So I've had an annoying little vibration/rattle whic is the downpipe slightly catching the ARB.

It's only occasionally happening when setting off, but is gradually getting worse.

Having a look underneath the car both front and rear engine mounts have seen better days.

With the rear engine mount slid all the way down in the slotted locating point.

So I jacked the car up, big timber blocks under the wheels, dropped it down again and undid the rear engine moint main bolt.

Jackes up the engine until the mount slid up in the slotted locating point.

Cleaned the mount up with solvent and a small stiff paint brush and filled in the gaps in the mount with sikaflex 221.

Then tightened the 17mm mount up with a big old bar so it's not going anywhere!

All in all this should give me 2-3cms of clearance and stiffen the mount up slightly too.

Cleaned the front mount and filled with sika 221 also.

I'll give it until Friday to drop it down on its own weight.

Will see how this goes but may keep my eye out for a full set of mounts and make my own PU bushes for them.

[Gaz2405]

First drive today with the mounts adjusted, much better sharper and with no rattles from the exhaust anymore. Bonus!


In for the clutch tomorrow along with rear wheel bearings and braided hoses for the brakes.