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Nelson's 2ZZ AW11

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NELLY G
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2015/09/15 00:40:36 (permalink)
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Nelson's 2ZZ AW11

Hi everyone,
This is the build thread for my 1987 Toyota MR2 AW11.

I've owned it for a little over a year now, and it's been a blast to drive. However, the original 4AGE engine is a little tired and loves to chew through oil. After much debate of which engine to swap, the 2ZZ was selected in favor of the Blacktop and Silvertop. I was able to acquire a ZZT231 half-cut much cheaper than a Silvertop/Blacktop Engine/Transmission package, plus a 2ZZ is somewhat unique compared to the common swaps.
So here is the half-cut (Originated from a '99 JDM Celica)

 
After a few hours of work tonight, this is how it stands. Parts have been removed in preparation for the removal of the engine.
I will try to update the thread as much as possible, documenting the process as I go along.
 
 
Also, if anyone has any of these parts, please send me a message.
SW20 NA Axles
MR2 Spyder Dipstick & Tube
1ZZ Idler Pulley
 
Nelson.
#1


39 Replies Related Threads

    Paw11
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    Re: Nelson's 2ZZ AW11 2015/09/16 06:31:43 (permalink)
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    Very keen to see how this goes.
    A couple of questions.
    What did the half cut cost?
    What side of the gearbox is the gear selector?
    Sorry I can't help with the bits you need - only a dub stuff in my shed.
    P
    #2
    Eric
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    Re: Nelson's 2ZZ AW11 2015/09/16 08:15:03 (permalink)
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    Hey Nelson, 

    Just be careful as the engine swap will not be P plate legal in Queensland

    Cheers, 

    -Eric

    1990 SW20 Hardtop - Supercharged 2GR-FZE
    #3

    NELLY G
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    Re: Nelson's 2ZZ AW11 2015/09/16 10:25:48 (permalink)
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    Update:
    A few more parts of the loom disconnected and labelled.

    Most of the time was spent trying to removed the seized CV shaft from the hub. Ended up cutting the ball-joint (seized nut also) to take the whole hub off.

    - CV Shaft out on the passenger side.
     
    Next up is to remove the CV from the driver's side, disconnect and label a few more wires/hoses, and the engine should be ready to come out!
     
    Theorist -
    The half cut cost $1550 from Just Jap in Sydney! Freight was an extra $275 to the Gold Coast. The gear selector is on the same side as the C52, so thankfully I don't have to reverse the shaft around! No worries! Thanks anyway.
     
    Eric-
    That's the least of my worries right now ;)
     
    More updates to come soon!
    Nelson.
    #4
    jerome.stojanovic
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    Re: Nelson's 2ZZ AW11 2015/09/16 16:57:51 (permalink)
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    That's going to be awesome. I have a 2zz spyder and am also on the GC so will be awesome to see it out. 
     
    #5
    barry
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    Re: Nelson's 2ZZ AW11 2015/09/16 18:54:36 (permalink)
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    Hi, i am interested in your build. Good on you for having a go at it. I was interested in why you need sw20 axels? Are they the correct legnth for the swap? Or will they have to be altered?
    #6

    xtimmyx
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    Re: Nelson's 2ZZ AW11 2015/09/16 22:47:02 (permalink)
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    Will follow with great interest! :)
    #7
    Knightrous
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    Re: Nelson's 2ZZ AW11 2015/09/17 08:24:10 (permalink)
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    The SW20 NA drive shafts fit the AW11 hubs and fit the diff in the C60 gearbox that comes with the 2ZZ. You can also build a 6 speed gearbox for the 4A AW11 using the same shafts, but fitting the C60 gear set into the C52 gearbox and swapping on the C60 5th/6th gear cover.
    #8
    Hoonsy
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    Re: Nelson's 2ZZ AW11 2015/09/17 12:00:46 (permalink)
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    Minty looking AW11. Lets hope you don't get too much trouble from the popo. 
    These cars turn heads, but I've never actually had any trouble so I reckon you'll be right. 

    How'd you manage to jump straight into it? I started getting into cars when I hit my red Ps and I still know nothing haha
    #9
    barry
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    Re: Nelson's 2ZZ AW11 2015/09/17 22:11:12 (permalink)
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    Knightrous
    The SW20 NA drive shafts fit the AW11 hubs and fit the diff in the C60 gearbox that comes with the 2ZZ. You can also build a 6 speed gearbox for the 4A AW11 using the same shafts, but fitting the C60 gear set into the C52 gearbox and swapping on the C60 5th/6th gear cover.


    So does that mean that the sw20 drive shafts are the correct lenght? And you don't have to go to the trouble of shortening 2zz celica ones?
    #10
    Knightrous
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    Re: Nelson's 2ZZ AW11 2015/09/18 16:16:01 (permalink)
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    barry
    So does that mean that the sw20 drive shafts are the correct lenght? And you don't have to go to the trouble of shortening 2zz celica ones?

    They require zero modification when using the C60 in a C52 case (using the 3 standard AW11 gearbox mounts) or if fitting a ZZW30 LSD into the factory AW11 C52. If you do the same thing with a 2ZZ and leave the gearbox in the exact same position, then it should also be fine.
    #11
    barry
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    Re: Nelson's 2ZZ AW11 2015/09/18 17:10:23 (permalink)
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    Thanks again.
    Nelson, i think its a great idea what you are doing. I would recommend getting an LSD for it and possible even a close ratio gear set to get the most out of your engine without having to get an aftermarket computer.
    #12
    sweeetpete
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    Re: Nelson's 2ZZ AW11 2015/09/18 20:20:55 (permalink)
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    Might have an LSD here. Make sure you check/replace the lift bolts too.
     

    2001 spoida black, remus exhaust C one spoiler Carbing braces.
    01spoida red track car turbo,omp seats,,cusco clutch/lsd C one strut braces.
    89 Aw11Sc.
    #13
    NELLY G
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    Re: Nelson's 2ZZ AW11 2015/09/18 22:56:35 (permalink)
    +1 (1)
    Hi everyone!

    Sorry for the lack of updates, I had a rest Wednesday night and was too tried to post last night, but here are the updates so far!

    - Me trying to look for a way to undo the two bolts holding the CV Shaft to the support bearing. Since the half cut was on a pallet, I wasn't able to access anything from under the car...If anyone else decides to go down this path I advise you to make sure you have access to the bottom of the car, it will make life much easier.

    -The two bolts out! I ended up lifting the front end of the car with the engine hoist and jamming an impact wrench under there to get them undone. Almost every bolt on this car was VERY TIGHT.

    - Today the engine finally came out! Boy what a job that was!
     
    All I have to do now is take off the dash so I can disconnect the body loom, and that should be it for the Celica!
     
    I still have to find the parts I mentioned above, as well as figure out what to do with the fuel system (2ZZ is based on a return less system whilst 4AGE is based on a return system). Until then, I don't want to pull the engine from my AW11 until I have all the parts I need.
     
    jerome.stanjovic - I think I've seen you around somewhere before! We'll have to go for a drive sometime once I get it running!
     
    barry- Thanks for the support barry! Knightrous explained the whole thing very well! I hope it helped with your enquiries! They seem I little out of my budget right now but I might be able to get them sometime down the track!
     
    Timmy- Thank you!
     
    Knightrous - Thank you for all the technical information! I didn't know that it was possible to swap in the 5th/6th gear set from the c60 to the c52 to make a 6 speed box!
     
    Hoonsy-  Thank you! I try to keep it as tidy as possible! Thankfully, I've never had any trouble from the police since I've owned it! Provided I don't go too extreme the police shouldn't notice anything out of the ordinary when it's all done anyway.  As for how I managed to get into it so quickly; I guess it stems from my interest in building and messing around with things!
     
    -sweetpete That sounds good! I've heard about the issue with the lift bolts! The engine has been maintenance very well from what I can see externally (There were recent service stickers on the engine plastics etc.) so I suspect the previous owner did everything they could to keep the engine running well, but it wouldn't hurt to check!
     
    Thanks again everyone for the support! More updates to come shortly.
    Nelson.
     
     
     
     
     
    #14
    rikkir
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    Re: Nelson's 2ZZ AW11 2015/09/19 10:26:36 (permalink)
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    With my MR2 half cut, i used an engine crane to lift the whole thing off the pallet and support on blocks so i could access the underside.
    #15
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