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Supercharged MR2 Spyder build

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kiwi
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Monday, September 28, 2015 10:00 AM (permalink)
5 (2)

Supercharged MR2 Spyder build

Thought it was about time i put this up here, I only started this build almost a year ago and its been a very slow progression so far.
Anyways the car:

And the "Complete supercharger kit that came off the sellers corolla" : 
After a lot of hunting on the web trying to find the install instructions that were not included i ended up getting them but could only find them in Japanese, Google was able to translate it but deleted all the photos in the process.
 
Anyways as i had pictures i could run off i started to make sure everything was there and i discovered that two brackets, all the wiring harness but 2 were missing and the fuel management piggyback that came with it was DOA (not like i planned o using it anyways) and other various pieces were missing too.
 
A few weeks later and lots of welding, grinding and macgyvering i had it in and was getting ready to take it to the tuner i had been using
 
Before:
 
After:
 
So on the first dyno attempt the stock ECU prevented the tuner from tuning the uni chip properly due to the Uni Q not having a injector driver and not having 100% control of the injectors, despite the fact I was meant to actually have a Uni Q plus...
 
After lots of saving i purchased a AEM EMS4, a AEM wide band fail safe, DeatschWerks 440cc injectors( the charger was suppose to work on a completely stock corolla) and a AEM water/Meth injection for cooling the intake charged (can't inter-cool)
 
The second dyno attempt was done after a new heavy duty clutch was installed with the help of Joel but i had electrical gremlins half way through the tune with my battery light coming on, i also found out that despite this supercharger kit being designed to only make a max boost pressure of 7.25 (.5 bar), on my car it reached 9.9 psi??? The boost was confirmed by both the EMS4 telemetry and the AEM fail safe built in boost meter, I used the pullies that came with the kit and the charger itself has a electromagnetic clutch pulley so it can't be changed without a lot of work going into it.
 
YouTube video of the car running on EMS4, it it still running quite rich but drivable here
That whine is addictive :D
 
Not long after that video I had to take the entire supercharger assembly out to get to my alternator out to test it as the battery light had started to come on a lot.
All but the rectifier was within spec with the rectifier not having continuity between the B+ pole and any of the screws that connect to the copper windings
 
Charger out:
 
Charger in:
 
I purchased a re-manufactured 2zz alternator from denso hoping that it would fix the issue but sadly after reinstalling everything the battery light still on.
I tested the fuses and the were fine and the fuse holders are passing a current.
It has again been removed and i gave it to my works auto electrician to have a look at to see if the alternator itself is the issue or if something was damaged during the weekend when the motor and transmission was dropped to swap the clutch as the issue did start to arise not long after that.
Hopefully i get news about the alternator soon and i can start to figure out what is causing the alternator not to energize and charge like it should
post edited by kiwi - Monday, September 28, 2015 11:49 AM
#1


18 Replies Related Threads

    kiwi
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    Re: Supercharged MR2 Spyder build Thursday, October 01, 2015 10:54 AM (permalink)
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    So the alternator checked out to be fine, and I've retested all wires and fuse holders that are associated with the alternator, my next guess is that parhaps there is a break somewhere in the B+ wire.
    Am i able to test the B+ wire for power like any other wire and it will show the batteries current volts or do i have to have the alternator running???
    #2
    seasalt
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    Re: Supercharged MR2 Spyder build Thursday, October 01, 2015 3:08 PM (permalink)
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    Following!
    2ZZ ?
    Had to build a box in rear of cabin where soft-top was?
    Is this a race only vehicle?
    post edited by seasalt - Thursday, October 01, 2015 3:15 PM
    #3

    kiwi
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    Re: Supercharged MR2 Spyder build Thursday, October 01, 2015 10:39 PM (permalink)
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    Like just about all other MR2 spyders that have positive displacement blower put into them i had to cut a bit of the firewall back but due to how the blitz kit sits compared to the TRD sits i had to cut a large chunk of fire wall out and then my neighbor and i welded up that box to fit over it.
    The soft top got slashed a few days after i got the actual kit and as i have a hardtop and it would of been easier to install without the softtop i removed it and cut the frame up to allow the hardtop to be installed.
    Its still the factory 1zz-fed motor but now that my boost gauge is reading just below 10psi at about 4000rpm (ems4 not tuned any enough to go past 4000rpm) I might have to look at geting forged conrods and maybe lower compression pistons.
    The car is road registered but is due to be engineered as it also has a roll cage too
    #4
    kiwi
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    Re: Supercharged MR2 Spyder build Sunday, October 04, 2015 7:34 AM (permalink)
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    It appears that the B+ wire and only the B+ wire has damaged as i registered 7-8 mega ohms of resistance and a 3 volt difference which only occurred when the B+ wire was connected to the alternator, it also failed to turn on the light tester
    I cut the old connectors off and used some 4 gauge wire to make a new B+ wire and it appears to be charging the battery and powering the car, took it for a 100km drive and the light didn't come one once!
    Now i just need to save to get the rego paid (mid November) then order some kuhmo ku36 for all 4 tires and then hopefully third times a charm with the tuning and actually seeing what it can do.
    post edited by kiwi - Sunday, October 04, 2015 8:30 AM
    #5
    aussiespyder
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    Re: Supercharged MR2 Spyder build Sunday, October 04, 2015 8:09 AM (permalink)
    0
    Glad to hear it's Sorted

    00' MR2 Spyder ZZW30R -
    03' RAV 4 Cruiser- 89' MR2 AW11
    #6

    kiwi
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    Re: Supercharged MR2 Spyder build Sunday, October 04, 2015 8:28 AM (permalink)
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    I just glad its hopefully sorted but the results sofar are promising.
    Its odd the problem only became apparent when the B+ wire was connected to the alternator
    #7
    kameleon
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    Re: Supercharged MR2 Spyder build Monday, October 05, 2015 4:19 AM (permalink)
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    Love it
    #8
    kiwi
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    Re: Supercharged MR2 Spyder build Monday, October 05, 2015 11:47 PM (permalink)
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    Well turns out that the original bad alternator and damaged B+ lead were the cause of a few other issues like the air con constantly blowing its 20a fuse and the insanely lumply idle the car had but unfortunately it still has the battery light only on startup sometimes.
    If i turn the car off then back on 2-5 times it will eventually turn the damn light off and be good for the rest of the day.
    Looks like more looking at the 4 wires is needed...
    #9
    Mrskylighter
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    Re: Supercharged MR2 Spyder build Tuesday, October 06, 2015 2:09 AM (permalink)
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    Could it be a grounding issue? Missing wire(s) from engine to chassis or dodgy battery negative lead or something?
     
    I know SW20s do funny things when certain ground wires are not connected (melt throttle cables haha)
    #10
    kiwi
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    Re: Supercharged MR2 Spyder build Tuesday, October 06, 2015 2:49 AM (permalink)
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    It could be that, ill poke around this weekend again to see if any ground wires are not connected but could one ground wire only affect the alternators abolity to charge?

    Maybe my battery is on its way out??? Its a optima yellow top thats about 3 to 4 years old but i was under the inpression that AGM cell batteries lasted alot longer than the wet cell equivalent?
    post edited by kiwi - Tuesday, October 06, 2015 2:54 AM
    #11
    kiwi
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    Re: Supercharged MR2 Spyder build Monday, October 12, 2015 9:35 AM (permalink)
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    So new cable seems to work well, i had to take off my rear drivers side axle to get the inner cv boot replaced and now my hand brake light stays on.
    It certainly does not feel like its on.
    Worked fine before i pulled the caliper off, which i did with the hand brake off so it would not close on itself.
    Am i meant to wind the piston back in even if i didnt change pads??
    #12
    kiwi
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    Re: Supercharged MR2 Spyder build Monday, July 10, 2017 9:03 AM (permalink)
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    Thought I'd finally update my build.
    I fixed the hand brake light that was always on (I dont remember what is was) and the reason the battery light was turning on was a damaged B+ wire.
    Since the last post I have completely revamped the fuel system and made quite a few changes
    It now has a 340lph fuel pump, I have removed the restrictive return less fuel system and upgraded that to a return one with a boost adjusting fuel pressure regulator.
    The entire exhaust has been redesigned (kept those PPE headers though) and it now is way better designed plus it uses a varex muffler so that's a bonus
    I have upgraded the stock oil pan to a Moroso oil pan (pain in the rear to install -_-) and also upgraded to a Mishimoto radiator and a 170 TRD thermostat (was a 180)
    But most important of all I have removed the biggest issue that plagued this build, that blasted EMS4!!!
    As it sits it is currently at castle hill performance having a Haltech 1500 elite installed and then tuned
    I will post a pic of the dyno graph and hopefully a video of it during a power run in the next week or so
    #13
    MCT_MR2
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    Re: Supercharged MR2 Spyder build Sunday, July 16, 2017 1:15 AM (permalink)
    0
    Glad to hear you sorted issues. The elite 1500's are great ecus, and thankfully you will have knock control seeing as you have the 1500 model. Your in good hands at castle hill, Dale is an awesome tuner, and knows the haltech product really well.

    '88 MR2 4AGTE W/ EFR6258

    224.6KW @ 20PSI

    more to come......
    #14
    kiwi
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    Re: Supercharged MR2 Spyder build Sunday, July 16, 2017 9:33 AM (permalink)
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    I got the car back on Wednesday and drove it home.
    Dale did do a awesome job on it and it drive almost like stock.
    Only two issue but neither is tune or tuner related but more SMT related.
    1. The SMT shifts from 1st to second very harshly but that is nothing to do with the tune but more to the fact that the car is running a standalone wired in as parallel to the standard unit, from a quick bit of google searching this is normal, The rest of the shifts a quick and clean
    2. From what Dale has told me the blower is too small for the engine and I start to lose boost from around 5000rpm, before that I have a solid 9psi but have fallen to 5psi by the time I get to the rev limiter and has unfortunately prevented me from making more power (I actually lost power except on the bottom end of the rev range I gained a little...)
     
    Whilst it was getting tuned I got Dale to see if he could get it to rev past 7000rpm (apparently SMT can't go past that??) he was able to do so with no issues what so ever and has set my rev limiter to 7500rpm (I have up-rated valve springs and stage 1 cams), so either the 6sp SMT do not have that rev limiter built in that the Americans have claim prevents a 2zz going onto a SMT or the Australia spyder do not but either way this Spyder is going the 2zz route now that Dale has discovered that I can and do rev over 7000, maybe I'll get a blower from a lotus and chuck it on that and go E85
     
    Unfortunately, I do not have a video and the car is currently unregistered (working on trying to get it blue slipped) so once it is road legal (cough cough) I shall get one of it and upload it
     
    On that note I still have the AEM EMS4 plus PnP harness I brought for this build. If any one is interested in this chuck us an offer (will trade for MR2 spyder parts also) as all it is doing is gathering dust. I will only sell this to someone who knows how to reference ecu wires and tune a ECU as I believe either the base map is rubbish or one or more wires are not correct. It runs and idles but will not go over 3500rpm when revved in neutral and stumbles and misfires (possibly) when any form of load is applied.
    Adam at J.E.M tried to tuned the car with it but was unable to due to unknown issues.
    post edited by kiwi - Sunday, July 16, 2017 9:51 AM
    #15
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