robk's MR2 Turbo
Hey everyone, welcome to the ongoing build thread for my heavily modified 1990 JDM SW20 MR2 GT, now with 5S-GTE engine. 
NOTE: My modifications list is after the photos below, and I always keep the list completely up-to-date! This is for my own benefit as much as others. If you want to know what parts I used for various things, there's a good chance you'll find the answer below. This is currently the largest thread on the forum, so the moderators suggested that I include this index of page numbers (just for the stuff that people are most likely to be interested in). These page numbers are assuming 15 posts per page: - Page 113: Dyno graphs, and photos of the engine bay in its current state. - Pages 38-40: Installation of white LED back-lighting in cluster, including how to eliminate hot-spots. Installation of Omori electronic boost gauge in stock location, including a custom PWM dimmer circuit designed by forum member 'cogs' (see here).- Page 98: Speedo conversion from cable-driven (mechanical) to electronic. I carried out the conversion in a way that no one else had attempted before.- Page 67: The front-mount heat exchanger and Johnson CM90 water pump for the A2W intercooler system.- Page 95: Photos of the PWR 'Type 1821' aluminium radiator and some info about it. - Pages 37 and 45: Engine bay photos and dyno graphs for the OLD engine mods, which were on the car from about 2011-2013 (the turbo used to be a GT3082R instead of a GTX3076R, the A2W intercooler setup was different, there was no E85 support, the ignition system was still distributor-based, the intake manifold/plenum was stock, etc).
- Page 9: Photos of the completely stock gen 2 3S-GTE engine and engine bay, after the engine was removed for the initial rebuild. 
1990 JDM SW20 MR2 GT
Power output:
- 418rwkw (560rwhp) @ 32psi on E85, on a Mainline dyno
- 289rwkw (387rwhp) @ 20psi on 98 RON premium fuel, on a Mainline dyno
Turbo and exhaust:
- Garrett GTX3076R turbo, 0.82 A/R exhaust housing
- Full-Race exhaust manifold and 3 inch dump pipe, ceramic coated in black
- Custom 3 inch stainless exhaust system
- Tial 44mm external wastegate with ~16psi spring
- 3 port MAC boost control solenoid (boost controlled by ECU, varying by gear and ethanol concentration)
Cooling/Intercooling:
- Frozen Boost 'Type 5' A2W intercooler core on top-left of engine bay
- Custom front-mount PWR heat exchanger for A2W intercooler system, sized for easy fitment while retaining A/C condenser
(the drawing number from PWR for the custom heat exchanger is PWH62619)
- Johnson CM90 electric water pump for A2W intercooler system
- PWR alloy radiator (type 1821) for main cooling system
Intake:
- RacerX side-feed intake manifold/plenum with phenolic spacer
- Turbosmart plumb-back BOV
- Plazmaclamps incorporated into interooler piping for reliability
- 60mm gen 3 throttle body (instead of the 55mm gen 2 throttle body)
- K&N pod air filter
Block and Head:
- 98+ 5S-FE block and crank (2.2L)
- Gen 2 3S-GTE head (ported)
- Wiseco custom forged pistons, 87.5mm, ~9.0:1 CR
- Cylinders bored/honed with torque plate
- Pauter 5S-FE rods
- ARP CA625+ rod bolts
- '1000hp' wrist pins
- Hux Racing billet steel main bearing caps
- ARP main studs, part number 203-5404
- King race main bearings and rod bearings
- Ross-Tuffbond Metal Jacket harmonic balancer
- ARP CA625+ head studs, part number 203-4207
- Hux Racing head stud support washers/hats
- ATS Racing 5S-GTE MLS head gasket
- Cam Tech staggered camshafts 265in/271ex
- Intake (Cam Tech part number 421B) advertised duration 265 degrees (225 at 0.05" lift), 8.7mm lift
- Exhaust (Cam Tech part number 439A) advertised duration 271 degrees (230 at 0.05" lift), 9.5mm lift
- Fidanza adjustable cam gears, Zaklee transparent cam gear cover
- Brian Crower valve springs and retainers, stock valves
- Supertech valve stem seals
- Shimless buckets
Fuel delivery:
- Flex-fuel, using a Continental-style flex fuel sensor (50-150Hz = 0-100% ethanol)
- RacerX fuel rail kit
- Injector Dynamics ID1700 top-feed fuel injectors
- Turbosmart 'FPR1200v2' fuel pressure regulator
- Twin in-tank E85-compatible Walbro F90000267 fuel pumps (separate relays in frunk for staged control by ECU)
- AN-8 braided teflon fuel supply line from tank to fuel rail
- AN-6 braided teflon fuel return line
- Injector Dynamics IDF750 fuel filter
Ignition System:
- Nissan R35 GTR Coil-On-Plug conversion
- Denso/Ford 'AGSP 22YE07' iridium spark plugs gapped to 0.5mm (0.02")
Oil system:
- Moroso oil pan/sump
- Remote oil filter under the car for very easy access when the car is jacked up
- Oil cooler mounted under the car
- Oil catch can (~1L) with custom internal baffling and drain to the sump
(the drain is positioned on the side of the catch can in such a way that it won't drain unless the can fills excessively at the track)
Engine Management and Sensors:
- Adaptronic e1280s standalone ECU
- Custom 36-1 crank trigger wheel, with Cherry hall-effect sensor
- Custom cam reset trigger on exhaust cam gear, with Cherry hall-effect sensor
- 4 bar MAP sensor
- Fuel pressure sensor (0.5 - 4.5V = 0 - 150psi)
- Innovate LC-2 wideband oxygen sensor controller
- GM air temperature sensor
- Bosch water temperature sensor in A2W intercooler system
Transmission:
- Later model E153 swap
- Quaife ATB LSD
- OS Giken R2CD twin-plate clutch
- CRW (Chico Race Works) heavy duty inner CV joints
- DeltaV gear shift selector rose joint and copper bush kit
- DeltaV shifter cable spherical bearing bush kit
- Kirkosaurus urethane inserts for front and rear torque mounts
Wheels and Tyres:
- Guards rolled front and rear
- Extended studs front and rear
First set of rims (for the street):
- Work Equip Anhelos (restored rims, replaced centre caps)
- Rear 18 x 9 +34, 255/35 R18 tyres
- Front 18 x 8 +34, 215/35 R18 tyres
Second set of rims (for the track):
- Linea Sport Super Spoke
- Rear 17 x 9 +38, 255/40 R17 tyres
- Front 17 x 8 +29, 215/40 R17 tyres
Suspension:
- KW V3 coilovers
- Cusco front camber top mounts
- DeltaV front sway bar reinforcement plates
- SuperPro polyurethane sway bar bushes
- Front ride height is 1.8 inches lower than stock
- Rear ride height is 1.6 inches lower than stock
Brakes:
- Front DeltaV BBK with Lexus LS400 315mm rotors and Nissan 300ZX 30mm aluminium calipers
- Rear DeltaV BBK with Mazda RX8 Sport 323mm rotors and later model SW20 22mm calipers
- Toyota 4-Runner 1 inch bore brake master cylinder
- Brake booster upgraded to 1995 SW20 slimline type
- Modified brake pedal (30mm higher off the floor) for easier heel-toe
- Braided brake lines
Exterior:
- Aeroware replica polyurethane front lip
- Autopista fibreglass side skirts
- Phoenix Power fibreglass rear corners
- Rear lights swapped from later model
- Targa top, steering fog lights, electric folding mirrors
Interior:
- Pioneer AVIC-F910BT DVD/NAV double-din head unit
- Pioneer 12 inch sub behind passenger seat in sealed custom enclosure
- Pioneer GM6400F amplifier
- Kenwood door speakers, stock tweeters
- Ecliptech Shift-P2 progressive shift light
- TRD 300km/h speedo (with electronic speedo conversion)
- TRD shift knob with new OEM shift boot
- Momo steering wheel
- Omori electronic boost gauge in stock location, with custom dimmer circuit
- Custom check-engine-light and tachometer behaviour controlled by Adaptronic ECU via a button, to show the values of many parameters on the tacho
- White LED back-lighting in gauge cluster
- 2-step/launch-control push-button
- Autometer oil pressure gauge, in cigarette lighter location
- Dandism MR2 floor mats
- Fire extinguisher
- Optima Yellow-Top battery
- Hux Racing engine lid support
I also have an engineer's certificate for the whole car.
post edited by robk - 2019/01/27 23:40:22