Gary's Track Day/Fast Road Weekend Car (1ZZ turbo) Now 2zz Turbo

Started by Gaz2405, March 11, 2019, 20:39

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1979scotte

Quote from: Gaz2405 on March 15, 2019, 11:29
Yes I'm hoping the seat backs aren't too wide, look like they should work seen plenty of wing back recaro's fitted.

@dan944 planning on fitting rad behind the front bumper, obviously not all of it will get air flow. But will have a proper measure up once its hear and see what can be done.

The ones I've seen fitted were stock fiat rads never seen one of those however I've got a japspeed mr2 rad and an Ali charge cooler rad and they both fit.
I will double check when I actually see my car again.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Gaz2405

This is apparently a direct replacement.....

I'd seen the lovely pro alloy ones and thought better of it!

Plus full alloy because race car.  ;D

1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Larger Injectors!!!

Whats everyone doing?

Dropped on some 2zz ones for £50, anything else I should look out for?
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

shnazzle

Are they going to be big enough? You'd be running pretty low boost I guess. Maybe some 440cc for future growth?
...neutiquam erro.

Gaz2405

Just looking to be pointed in the right direction really. Any oem ones that fit?
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

shnazzle

Quote from: Gaz2405 on March 15, 2019, 20:23
Just looking to be pointed in the right direction really. Any oem ones that fit?
Yup. The lotus ones. They're green. Or, astra vxr 630cc I believe? Need a tiny bit of Stanley knife work to get to fit. Again... Dan knows best :)
...neutiquam erro.

1979scotte

Google is your friend.
SP Turbo used 440cc so they must be readily available for reasonable money.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Gaz2405

Got a spare couple of hours today on the car, so I quickly moved things around in the garage and managed to squeeze the two in.

Started about removing the exhaust manifold and having a general  nosey around the engine bay.

I was quite surprised/annoyed at the amount of bracing and brackets there are holding the manifold in place!

Any way all off, only 1 bolt that has to be drilled out on the heat shield.

It looks like there is a high pressure oil journal on the front of the block that has been tapped before and now has a copper plug in, anyone else have this?

Looks to be in a perfect location for the oil feed for the turbo.

If I get some time tonight I'll mount up the turbo manifold and see how it sits.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

#33
Scrap that it's a coolant drain or bleed valve.

Here's the pre cat mess I had,  not sure if this is a lot of break down or not... Anyone?

https://flic.kr/p/RrVRMz

1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Topdownman

I would be concerned about that dust from the pre cat as the important thing when they come out is that they are intact before you start to remove them.
"Racing" tax disc holder (binned), Poundland air freshener, (ran out), Annoying cylinder deficiency,  (sorted),
Winner of the Numb bum award 2017
Readers Ride

06 not V6 readers ride

Gaz2405

Going to try and pull the plugs today and have a visual inspection of the cylinders.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

dan944

I used Siemens deka injectors. 670cc. I think they were about £140 for the set and need a little modifing but it's very easy. Spyder lee has a video on it.
Not sure what duty cycle they run at but there were no complaints whilst tuning.

"I swear mum I did try and sell the roadster"

Silver mr2 2003 FL. Custom Turbo build 209whp. Lots of handling mods.

Honda CR-V The Work Horse

1979scotte

Quote from: dan944 on March 18, 2019, 10:16
I used Siemens deka injectors. 670cc. I think they were about £140 for the set and need a little modifing but it's very easy. Spyder lee has a video on it.
Not sure what duty cycle they run at but there were no complaints whilst tuning.

Manufacturers usually run a duty cycle of 80% plenty of head room left for safety's sake. Whoever tunes the car may have their own opinion.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Gaz2405

Few bits done tonight.

Relocated battery to lower cross member using the midship runabout guide, very easy.

This should leave plenty of room for the charge cooler, expansion tank and oil catch tank.

Test fitted manifold and turbo and clocked the cold side by 90.

Ordered downpipe and sports cat.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Right thought it was about time I updated this on whats been going on.

Managed to get the turbo mounted to the manifold using an adaptor plate to go from T3 flange to T25 flange that the TD04 15t uses. Also done carbon canister delete and moved the battery down to the rear subframe.

Had to drill out the tapped holes in the turbo as the flange adaptor was threaded.



Oil lines on.



Also got the new seats fitted, they came with clio 182 subframes which were duley butchered to fit the MR2, I've gone for mounting them straight through the floor as low as possible and used spreader plates underneath the car. I'll replace the individual spreader plates at a later date with plates welded to the floor and nuts welded to them.

But so far loving the look and feel of them.





I've gone for a sports cat and down pipe from Lewis, which will need some modification to fit but shouldn't be a problem.





Manifold and turbo insitu.



Autosilicone hoses have messed up by order for the parts needed to fit the charge cooler so that's due later this week.

Next up is, dropping the oil and sorting the oil feed, oil drain in the sump and oil cooler.

After that it will be charge cooler plumbing, then on with the gauges.

Also still waiting on my braces from Megillian Motorsport have been told they'll be here soon, so fingers crossed.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Managed to grab and hour or 2 on the car tonight.

Test fitted charge cooler and pipe work and mounted up expansion tank.

Currently got a MAF adaptor pipe to get running to start with, but also have another pipe to fit IAT.







Still waiting on the hose clamps, a 45 degree bend for the throttle body to give a nicer connection, correct size pipe work for charge cooler rad and a few other bits.

Exhaust flange ordered and some stainless to extend the down pipe.

1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

mr2turboguy

MR2 ROADSTER TURBO @ 205HP
Meister R Coilovers, Black Dials, Rota Wheels, AEM Boost Gauge, Custom Pillar Pod, Garrett GT2860RS turbo, AEM Meth injection, EMU Black ECU.

Gaz2405

Been a while since I last updated or even worked on the car as my day job got in the way! The cheek of it!

Anyway, Oil feed and oil drain lines both connected up.

Water hoses intersected as per the TTE document and touted to turbo with a 16mm to 10mm brass reducer and ran it in some braided hose to the turbo.

Sump off.

New sump fitted with threaded drain in.

Whilst sump was off, took oil filter off and a fitted sandwich plate for oil pressure, oil temp, oil feed for turbo and also feeds for oil cooler to go in behind drivers side side vent.

Hopefully get the hose ran for the charge cooler next.

Bodged together a down pipe for the turbo to feed into Malian exhaust down pipe. Enough to drive it to get a full system fab'd up anyway.

No pictures as technically I've been "working from home" today so it was just a case of getting stuff done.


One question though, what sump sealant are people using?? As I've just whacked the sump back on for the time being with no sealant and left the oil out of the car.

 
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Alex Knight


Gaz2405

She runs!!

Ish...... 😂

Fired her up today with charge cooler disconnected so I wouldn't see boost, ran perfectly. Waste gate also wired open.

No fluid leaks, exhaust is working as it should, still running two pre cat lambda sensors and one after in the stock location.

Brilliant I thought.... Connect up charge cooler, take it for mapping....

As soon as the cooler is connected I get about 10 seconds of rough idle, then it dies.

P0100, P0101 and P0110 all coming up, so obviously have a maf issue.

Tried moving the maf pipe further back in the system, helped a little but not much.

Going to give the maf a good clean and check the wiring.

Any ideas....??

From research it should at least idle and run on very low boost enough to drive and get it to the mappers.

Don't really have the time for it at the moment as worn has been mental busy, so I'm not missing driving it at least.

Cars don't you just love them!
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

So it's definitely a maf issue.

MAF wasn't damaged taking it out, but the wiring looks like it's been messed with in the past so I'm suspecting a wiring issue somewhere.

Unplugged maf car ran fine dint stall or hesitate.

Now to get AFR, and rest of the gauges working, then time for ecu and map.

Not sure when I'll get chance to work on it again, hopefully in the next couple of weeks.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Bit more done quickly this morning on the car and a few pics for an update.

Gauges in, just need to wire senders up, when the car is next jacked up. Ran the wires through the existing grommet in the engine bay, into some conduit in the cubbies and don the centre console.

Don't worry the parrot is going!



Basic down pipe from some 2.5" 90 bend, its plenty good enough to get it going and if you were on a really tight budget would probably do.







Oil Cooler fitted behind drivers side vent/pod.



Also gave the seats a bit of minor adjustment, as I wasn't completely happy with how they were sitting, still not 100% but didn't have much time.

Work horse and camper in the back ground.



Finally this morning the car moved under its own steam for the first time in a long time, few little niggling bits to do then off for ECU and mapping!

Will most likely put it in for new clutch before its mapped.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

thetyrant

Good progress :)   and interested to see how it maps up and power levels etc, did you decide on Ecu choice ?

You will most likely need to do some work on exhaust to get decent numbers as stock pipework is too small for much over 160hp and starts to cause restriction from what ive read,  going to 2.5" right through including silencer is the key and its good for 230hp+ then :D

Im hopefully going for a rotrex on my 1zz later this year so  interested to see how your chargecooler setup pans out and will be picking your brains im sure :D

Keep up the good work.

Ex-2005 roadster  owner, i will be back :D

Gaz2405

Quote from: thetyrant on June  4, 2019, 16:02
Good progress :)   and interested to see how it maps up and power levels etc, did you decide on Ecu choice ?

You will most likely need to do some work on exhaust to get decent numbers as stock pipework is too small for much over 160hp and starts to cause restriction from what ive read,  going to 2.5" right through including silencer is the key and its good for 230hp+ then :D

Im hopefully going for a rotrex on my 1zz later this year so  interested to see how your chargecooler setup pans out and will be picking your brains im sure :D

Keep up the good work.

Yes exhaust will get completely reworked, although I'll probably try and keep the sports cat from Malian as its new.

Going for ECU Master.

Will keep a look out for your build.
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0

Gaz2405

Few more little bits ordered last night to get things moving along again.

Couple of AN fittings to neaten up the charge cooler pipe work.

Bits of conduit to neaten some engine bay wiring.

Bumper and lights put back on to make it look a bit more car like again.

Spare down pipe flange for the exhaust fabricator to use.

Some 630cc Injectors, 2zz ones will be going up for sale.


Going to look into sourcing some different under car bracing as well.

The stuff I ordered from Megillian still hasn't turned up with various delivery dates missed, "48 hours from the powder coaters blah blah blah!!" I paid for them in full in March........Its now June!!
1zz turbo. Home built and home mapped.

Now 2zz turbo. Home built and home mapped

Build thread https://www.mr2roc.org/forum/index.php?topic=67004.0