MadMigMR2 monocraft GT300 2ZZ Swap

[MadMigMR2]

The long lasting 1ZZ is the only reason i didn't open this thread first  :sadbanana:

But finally on the end of the year i've made the final step that was missing...

1. Going to the UK for the new year's with 1 way ticket...
2. Going from the Airport directly to a car dealer and buying a 2002 Corolla Tsport with 70000 Miles (proven by a full service history on official dealer including a large amount of invoices)
3. Spend the New Year's eve on London
4. Drive back to Portugal (1800 Miles)  splitted on 2 days with a pit stop at Le Mans  B)

A picture at Ace Cafe in London


VVTLI Check:

The sound is not the best but the feeling was there.
I did some testings during the road trip and the engine looked very healthy.


What better to start the year than a Road Trip  :driving:


My car at the moment has the following specs:

Exterior & Suspension
- monocraft GT300 bodykit
- Braid 15" Wheels (with proper offset to match the bodykit) on Toyo R888 (205/50 front and 225/45 Rear)
- BC Racing Coilovers
- CHE Rear Arms
- All the Bars & Braces (TRD Replicas)

Engine:
- 1ZZ-FE (revised version with 120.000 KM with some oil consumption issues but probably only related with the valve seals...)
- Custom intake (behind battery)
- TRD Headers
- CHE Downpipe (No cat)
- CHE Dual Can central exit exhaust (lotus style)

Electronics:
- Apexi PowerFC (for 1ZZ...)
- PLXDevices.com Wideband kit + Wifi connection kit (NEW)

2ZZ Parts list Owned:
- 2ZZ-GE Engine (DONE)
- 6 Speed GearBox  (DONE) - Will need to transfer the LSD from my gearbox to the "new" one. Other option would be buying a LSD and install on this gearbox.

2ZZ Parts List Wanted: (UPDATED 2013-01-16)

- Apexi PowerFC 2ZZ
- PPE Header
- PPE Downpipe (no cat)
- Competition Clutch Flywheel (same has MWR ultra lightweight flywheel)
- Competition Clutch Stage 2 Clutch
- 2ZZ Engine Mount
- MWR Dip Stick
- MWR Reverse Blockout
- MWR Shifter Shaft
- Water Pump
- ARP Head Studs
- Moroso Pan
- Oil Cooler Kit
- new belt with right measure to fit with the 1zz ac compressor
- MWR Alternator Pulley
- MWR Water Pump Pulley
- MWR Valve Steam Seal Kit for 2ZZ-GE


Head work:
- port & polish work
- MWR Valves
- MWR Titanium Retainers
- MWR Springs
- Stage 3 MWR Cams


Things i know that needed to be done:

- TPS wires change
- use 1ZZ Knock Sensor
- use 1ZZ AC Compressor
- use 1ZZ Fuel Rail


Next weeks will be made collecting more information and price quotes and then i'll start ordering material  s:) s:)

I'm since today back in Luanda, Angola working but left the 2 cars on the shop in Portugal were they will start getting both engines out of the car and start working on the 2ZZ Engine.

Any information is more than welcome  s:) s:)

I've already collected many information from some great threads on both mr2spyder.net and spyderchat and i'm compiling everything to help the most i can the people that will be working on the cars.

The objective is having the car ready to be tested and dyno tuned on 20 of April, the day that i return to Portugal.

So basically i have 3 months to collect everything i need to have the car up & running  :driving:

Work in Progress....

1ZZ getting out
 







Corolla still with the 2ZZ and without some parts already sold  s:) s:)

[MadMigMR2]

Yesterday's progress:

Engine and all the bits out and a full cleaning job done




Ready to rest for a wile...


Next victim:

[StuC]

Wow, that is some lengths you have gone to in order to get your new engine!!
Awesome road trip!!  s:lol: :lol: s:lol:

Have you give yourself a deadline to complete the transplant?

[MadMigMR2]

Wow, that is some lengths you have gone to in order to get your new engine!!
Awesome road trip!!  s:lol: :lol: s:lol:

Have you give yourself a deadline to complete the transplant?

Now this is a tricky question to answer years later   s:mrgreen: :mrgreen: s:mrgreen:  

I've been working in Angola for the past years and the project had some issues that i could not control remotely.

The mechanic that started the project left the shop and i didn't know the new one and had no good references.
They assembled the engine with all the new stuff i bought, but the engine was never installed on the car due to my trust issues on the job they made.

So last year i've opted to move everything to a friend (scorcher) that had allready made a 2zz swap on a MR2 and does everything with big attention to the details

You can check is first 2zz swap here: http://scorcher.weebly.com/toyota-mr2-2zz-220cv.html

My option couldn't be more right after what we found on engine build, here's some info: http://scorcher.weebly.com/mr2-monocraft-gt300-2zz.html


The engine is now being built and i hope very soon it will be finished   s:bounce: :bounce: s:bounce:

[alancsalt]

TPS wires don't need reversing if throttle turns in same direction.

If the Corolla 6 speed is a C64, top gear is .815 to 1. The C60 from Celica uses .725 to 1.
If your gearboxes are the same as Australia then Corolla C64 differential is 4.52 to one.

Your MR2 would be 3.941? (Australian MR2 gets 4.312 to 1.) You would need a 6 speed main-shaft to swap that ratio into the Corolla box as one diff gear is on the main-shaft. The five speed main-shaft is shorter and won't fit, but the LSD can be swapped over. The selector shaft is different too. I bought a selector shaft from MonkeyWrenchRacing in the States.
I changed top gear in my C64 to .725 to 1, and had the 4.312 LSD put in. Depends whether you want the tall gears for distance driving or not?

Looks like you're doing a good job of it.

[MadMigMR2]

TPS wires don't need reversing if throttle turns in same direction.

If the Corolla 6 speed is a C64, top gear is .815 to 1. The C60 from Celica uses .725 to 1.
If your gearboxes are the same as Australia then Corolla C64 differential is 4.52 to one.

Your MR2 would be 3.941? (Australian MR2 gets 4.312 to 1.) You would need a 6 speed main-shaft to swap that ratio into the Corolla box as one diff gear is on the main-shaft. The five speed main-shaft is shorter and won't fit, but the LSD can be swapped over. The selector shaft is different too. I bought a selector shaft from MonkeyWrenchRacing in the States.
I changed top gear in my C64 to .725 to 1, and had the 4.312 LSD put in. Depends whether you want the tall gears for distance driving or not?

Looks like you're doing a good job of it.

Hi Alan,

Thanks for the tips!
Is there any way to find the model of the gear box ? Are there any codes on the outside i should check?
The first shop has already swapped my lsd from my stock 1zz gearbox to the 6 speed that came in the Corolla. Since the engine and gearbox came from the same car i guess it's everything ok

[alancsalt]

Since then I've seen conflicting info on the TPS, some say it's the direction it turns, some say it's the wiring that's reversed. That's the internet for you.

I don't know if there's anything on the box to indicate which one it is. I'd suspect C64, which means shorter gearing.. maybe easier to stay in "lift" but higher revs cruising. You'll know once you get it going. Personal choice - may not matter to you.   s:) s:)

[Anonymous]

Wire swap is due to the voltage being the wrong way, so a wiring issue.

[MadMigMR2]

Project Cars... Some say 4 years are the usual time for a project car.
In my case due to so many reasons it took a little bit more 

But, the time has come to finish it!
It was waiting some final details but due to being away from Portugal the car was waiting for this finishing touches for almost a year now.


Some years have passed and finally 2 days ago it was time to try the first start of the car...

http://www.youtube.com/watch?v=qkxjpuncYPk


2ZZ-GE First Start with 1zz ECU to check if there were any issues with the wiring!
We were almost sure that the immobilizer was doing some weird stuff and decided to reconnect all the wires related with the immobilizer and test the engine this way!


This is the first starts of the engine! You can listen to the evolution of the stock ECU adapting and the sound getting better and better.


Now it's time to install the AEM EMS-4 and have it properly tuned!


This is a high compression fully built engine with a compression ratio of 12.5:1


It gains rotation pretty quickly from this first starts with very low movement on the throttle!


BUILD SPECS:


BLOCK:
- DP Engine Parts (Forged Pistons & Rods) weight balanced to the decimal of a gram
- Fully balanced crankshaft


HEAD:
MWR Stage 2 Cams, Valves & Tit. Retainers & Springs
- Veicomer CNC Head Work including CNC Dimpling on the Air Intake Channels and Polished on the Exhaust Channels


DRIVELINE:
- OS Giken Flywheel and Clutch Kit
- LSD Dif from stock 1ZZ inside the 2ZZ gearbox from the donor car (UK Spec Toyota Corolla T-Sport)


INTAKE:
- PPE Custom Intake Kit


EXHAUST:
- PPE 4-1 Race Headers + 65´ Custom Exhaust with 1 High-flow Catalytic Converter + 1 large muffler with 2 side exits


ELECTRONICS:
- AEM EMS-4
- PLX Devices Wideband + Oil Pressure + Oil Temperature + multi-sensor touch screen display & Wifi link for connecting trough Apps


Here's all the details of the assembly from my Engineer Portfolio

[StuC]

@MadMigMR2 congratulations on getting it fired up!!
Great build thread. Loving some of the pics, especially with the micrometer.

[MadMigMR2]

Like any project, there is always one more little thing....

So...
AEM methanol injection kit ordered...
The idea is to have it working as a safe feature to inject meth when the lift is actuated!

We are now one a stage of having everything tidy in terms of wiring, protecting all the new sensor wires and main engine wiring loom with flexible plastic tubing, duct tape and, after we have the AEM EMS-4 tuned, we will Use higo temperature  fabric tape to finish the job.


After the first start with the 1zz Ceu, we swapped to the 2zz Ecu and tried to test drive the car, but our PLX Devices wide and was showing lean numbers just with a tap of the throttle...
So yesterday we decided to put the Apexi PowerFC for the 1zz and test it!
We have only idled the car and played with the compensation settings to lower the timing and add more fuel on all the map.
Today we will do our second driving test to see if we can at least do inspection with the car before we go to the tuning shop and dyno tune the car with the AEM EMS-4

[shnazzle]

Mate that is an absolutely amazing write up.
Well done and looks great!

I'm surprised it fired on 1zz ecu

[m1tch]

Looks a good build and well thought out I do have a couple of questions though:

What engine bearings did you go with? Bi metal/Tri metal etc?
Did you measure the little end size on the piston/pin/rod?
Did you fit sleeves to the block as the 2zz can't be rebored?
What are the flow figures for the head before and after? Interested to see the gain over and above the Yamaha optimised setup.
Are you running an accusump?
What gearbox upgrades did you do in terms of gears? JUBU or SSC?
Are you running underdrive pulleys for the water pump to stop cavitation at higher RPMs?
Are you running ARP for the mains, head and flywheel?
Guessing new lift bolts?