Mid Engine, Bolt On Goodness..

[saxolover12]

Meh

the MR2 we have owned for about 6 years now and TBH its never actually gone wrong...never broke down, only ever asks for tyres and brake pads.., its the light version of the MR2 with no ABS or traction control etc etc, weighs around 1200kg or maybe less with the amount of crap i have removed from the engine bay recently

with the sale of the GTR and me buying a lardy 300bhp mercs N/A i thought it would be nice to have a decent turbo car for the friday night burn

spec is...

GT3071R, polished, V band option, 4" inlet
motoria (xs power) manifold
XS power downpipe
XS power external wastegate (life expectency= not very long...)
XS power intercooler with shroud and spal 8" puller fan
VSV, TVIS removed
Custom billet fuel rail
870CC Delphi Injectors
FSE adj regulator
aquamist H20/ethanol injection
EGT guage
AEM wideband
oil pressure guage
boost guage
link ECU
expected power output somewhere around 400bhp hopefully


this is an ongoing build, ill be ading pics over the next few days/weeks

3071R





intercooler with fan



current state of progress..



everyone seems to take the stock route for the inlet pipe which is over the top of the exhaust manifold...TBH there is not an ideal route for the inlet, wherever you try to put it there is heat nearby

i tried to go under the car rather than above the hot manifold, i can say for sure that this is better but if nothing else its different (havent seen anyone take this route)


i used 60mm flexi pipe and a 45 degree bend, heat wrapped for good measure




downpipe heatwrapped



dry fit





not much room down there but we can keep an eye on inlet temps..

opinions welcome

[saxolover12]

sard fuel rail with delphi injectors, i kept the stock loom and used adaptor harnesses to go from aftermarkt injectors to stock loom








link ecu with stock loom adaptor fitted







seeing as were on the subject, WI pump and injection point

[saxolover12]

started it up for the first time today after about 8 months,. a coupleo progess pics..

the inlet looks incomplete but its all connected up

[saxolover12]

well we just finished mapping it at 1.2 bar on the 3071..

still on stock engine/gearbox/clutch, just bolt ons

95 octane fuel and a 90% ethanol mix in the WI

inlet temps were recorded via a AEM sensor and even though we were really hammering the throttle we saw 32 degrees inlet temp maximum when on boost (ambient was around 22 degrees today maybe more)...this is with the XS power intercooler and as above alcohol injection, without WI we saw 60's pretty quickly

i have datalog to prove the above as some may simply not believe me on this and i dont blame them really lol

the only failure we had was we broke the bearing in the recently replaced alternator, ill be fitting another one tomorrow hopefully

so, now lets see how long this engine lasts....as mentioned before in this thread i build engines so if it does go bang its no big deal really although i would like it to survive until it comes off the road for winter

[saxolover12]

i had the car mapped on 95 ron with aquamist pump and aquamist red jet set to about 7psi with 80%-90% ethanol/h20





here is a snippet of the timing map for those that are interested.. and below that is another stock MR2 engine on Vpower with no WI








http://www.youtube.com/watch?v=joU7AiKQE9A

power run
http://www.youtube.com/watch?v=joU7AiKQE9A


graph



looks like it makes good power pretty much all over the rev range

still on the stock engine/headgasket/clutch etc and still running 95ron, its used every day too..

[jav786]

Nice Work, this car Julie had/Has?

[saxolover12]

Hi Saj, yep thats right...Julies car (or Brians weekend car )

[saxolover12]

just updating the thread with current progress...


this manifold has cracked for the third time on the wastegate to collector weld, its a bit of an odd place to crack TBH so i had someone weld it back up and they added a couple of braces to the wastegate to hold the weight but....it cracked again :clap:

i have now sent it away to be welded by someone whos a bit more used to doing this type of work, lets see how it goes after that :-k

pics of said crackz...






whilst its off the road i took attention to the ignition system

seeing as my distributor has started to leak a little oil into the cap it seems a logical time to upgrade the ignition system, i went for 1zz coil on plug type with inbuilt ignitor seeing as the link ECU can control multi coil setup

nice and cheap too...the coils were second hand from a low mileage yaris for £30 and i got the loom from a rav4 for £8


current dizzy/HT lead system







the coils are a very loose fit into the 3S-GTE cam cover so i cut the original HT leads and slid the silicone jacket over the coil to brace them like stock







coil dry fit






the coils have four inputs, looking into the back of the plug
no1= ground
no2= trigger (wire to ECU output)
no3= IGF (not used)
no4= IGN live

i chopped the rav4 loom so i had a good length of wire and replaced the sheath


just for my own reference the wiring is as follows

cyl/loom-G4 output

1/black-blue orange
2/green-blue red
3/blue black-blue brown
4/green black-blue



coils fitted



i needed to shave the outside of the coilpacks on cyl 2/3 to clear the centre cam cover mount thing but other than that it was quite straightforward

[saxolover12]

just adding to this thread as i go....

decided to fit a swirl pot due to a lack of confidence in the fuel supply system, seems to struggle at low levels..

i added a 2lt swirl pot, large pump to feed rail, moar braided and aero fittings

placement was however quite restiricted....being the partners daily rive i was banned from using the boot area so i took another controversial step lol

swirl pot fitted in engine bay, custom alloy base









yes ill be monitoring fuel temps...

[saxolover12]

some cooling mods...ill let the pics speak for themselves









cheap ebay fans, had a friend cut the plate for me, total cost was about £60

[saxolover12]

very shortly after fitting the engine fan kit to the MR2 it rained lol

engine developed a misfire due to the sparkplug holes filling up with water....

something had to be done

ill let the pics speak for themselves...















it seems to keep the rain away from the rocker cover quite well, no misfire developed after it rained again

[saxolover12]

grip....most of us need more of it

its currently on annorexic alloys, thinner than the stock rims

bought some of the scabbiest rims i have ever seen and had some refurb work done

fronts


rears



yea clearance is fine...loads of room:disappointed:



flush









i asked for black and silver...when i got there they had done black on gold, i dont know if i prefer it




































i replaced the bolts with A4-80 grade fixings, not the best colour but strong and will not corrode quickly

i painted the calipers gold...i dont know if i like it, i may go black if it keeps catching my eye but i did hope they would dull off with a bit of heat and dust







Many thanks to Brian Neve for coating these for me.



hopefully mapping this again early next month, its been sitting in the garage far too long

[saxolover12]

at this stage the car was remapped for 20psi, power was around 350bhp but at this point the GT3071R failed due to oil starvation....this sucks!

fitting a restrictor as per garrett recommendations was the wrong thing to do, the turbos are allready supplied with an internal restrictor and you should ignore garretts recomendations IMO, they talk ****

garrett have no technical helpline, no phone number at all TBH, no address, no email address, no warrenty...in fact i dont even know what country they are based in, the worst customer service i think i have ever come across, if i sold nitrous products like this someone would have beaten me up by now

[saxolover12]

anyway...back to work, we cant let this stop us can we?



with the turbo rebuild in hand i decided to get a friend to fabricate an adaptor to allow for top fitment of the turbo on the stock manifold, an idea i stole from ther american forums, i have also enlisted the help of a GT3582 to replace the broken GT3071R whilst a rebuild attempt is made (unconventional, no rebuild kit is avaliable for this turbo)

here it is in the fabrication process







many thanks to Dewis Motorsport for their fabrication work

[saxolover12]

manifold adaptor dry fit for those that have any interest, it has about 1 inch of clearance from the heatshield






a few pics of clearance at the back of the top mount turbo, its going to need a little rework and even then it will still be tighter than a nuns ass....more so when the bigger turbo is fitted!



its tighter than it looks...the cold side is touching the heat shield just behind that stud!

[Gordo]

Those are damned tough little engines - there was a chap in Aussie who was playing around with turbo's on a stock engine, I think he ended up with around 420HP - AT THE WHEELS!
it actually peaked higher on one instance when he tried using NO2 on the intercooler to reduce intake temps - unfortunately it got sucked into the engine, the rev's took off and it ended up with a blown head gasket from the studs stretching. I remember he stripped it down to check but don't recall if there was any other damage.

[dewismotorsport]

I still think you'll be able to dent that heat shield in around the turbo, wasn't a bad guess to say I only had a photo to go from when I was making it, I'm sure I could notch a V out of it and re weld it if you want mate

[saxolover12]

you done a great job dewis, it just needed a fettle to make it fit better....the guy round the corner from me charged more for the fettle than you did to make the whole dam thing inc pipes and delivery!!!

managed to get a bit more room but changing the angle of the turbo flange on the manifold slightly, even with the bigger turbo it seems to have enough clearance





GT3582 on stock internals anyone? :-$

[dewismotorsport]

Ha ha that's typical, should of let me do it ;-)

[Benn]

Funk me that's jammed in there. Nice build, gold and black wheels are nice, not a fan of the 3spoke tho...

[rc]

great build, and we thought we had trouble in nova bays

[saxolover12]

the 3 spoke whels come from the same era as the car so i thought they suited, glad you like the black and gold though.....wasnt too sure about that myself lol

there is normally quite a bit of room for the turbo to fit, i just made life a bit harder because i wanted top mount and its nice to have the stock manifold back seeing as i have been having the aftermarket ones welded back up right left and centre