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AnsweredHot!robk's MR2 Turbo

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robk
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2009/12/17 01:58:47 (permalink)
5 (2)

robk's MR2 Turbo

Hey everyone, welcome to the ongoing build thread for my heavily modified 1990 JDM SW20 MR2 GT with Gen 2 3S-GTE.
 

 
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 99: Photos of the engine in its current state. 
- Page 100: The most recent dyno result.
- 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 16: Photos from the early stages of the engine rebuild.
- 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, Gen 2 3S-GTE


Power output:
- 386.2rwkw (518rwhp) @ 30psi on E85, on a Mainline dyno
- 300.8rwkw (403rwhp) @ 24psi 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:
- 2.0L gen 2 3S-GTE block
- CP forged pistons, part number SC7450 (86.5mm), ~9.0:1 CR with a 1mm HG
- Eagle rods
- Ross-Tuffbond Metal Jacket harmonic balancer
- ARP head studs, part number 203-4204
- ARP main studs, part number 203-5404
- Gen 2 3S-GTE head (ported)
- Cometic head gasket, part number C4314-040 (0.04", ie. 1mm)
- 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
- Shim-under-bucket conversion
 
Fuel delivery:
- Flex-fuel, using a Continental-style flex fuel sensor (50-150Hz = 0-100% ethanol)
- RacerX fuel rail kit
- Injector Dynamics ID2000 top-feed fuel injectors
- Turbosmart 'FPR1200v2' fuel pressure regulator
- E85-compatible Walbro in-tank fuel pump, part number F90000267
- Upgraded fuel pump wiring with a new relay under the dash
- AN-8 braided teflon fuel supply line, from pump to rail (removed standard hard line above tank for fuel supply)
- AN-6 braided teflon fuel return line, until the hard line (retained standard hard line above tank for fuel return)
- Speedflow AN-8 fuel filter with stainless steel mesh element
 
Ignition System:
- 1ZZ Coil-On-Plug conversion with RacerX adapter plate
- Denso/Ford 'AGSP 22YE07' iridium spark plugs gapped to 0.5mm (0.02")
 
Oil system:
- 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-1 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
 
I also have an engineer's certificate for the whole car. 
 

 

 

 


 
post edited by robk - 2017/09/29 09:41:45
#1
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1589 Replies Related Threads

    MR2QIK
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    RE: robk's MR2 Turbo 2009/12/17 02:03:48 (permalink)
    0
    Very nice & clean mate. Keep it that way.
    #2
    Nightingale
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    RE: robk's MR2 Turbo 2009/12/17 02:07:12 (permalink)
    0
    Very nice car rob, I assume you are the one I met up with the other day to talk about the adaptronic? :) Your car looks very nice.
    #3

    robk
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    RE: robk's MR2 Turbo 2009/12/17 02:12:24 (permalink)
    0
    quote:
    Originally posted by Nightingale

    Very nice car rob, I assume you are the one I met up with the other day to talk about the adaptronic? :) Your car looks very nice.



    You must be Jeff right!?
    #4
    bass6153
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    RE: robk's MR2 Turbo 2009/12/17 02:55:05 (permalink)
    0
    love the dish at the back and the exhaust looks pretty sweet got a sound clip of the noise it makes :D?
    #5
    Geo
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    RE: robk's MR2 Turbo 2009/12/17 10:35:53 (permalink)
    0
    great looking car you got there, you got the exact same wheels as me, I think it suits it really well without killing the beautiful stock look that the mr2 was born with
    #6
    Nightingale
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    RE: robk's MR2 Turbo 2009/12/17 11:33:04 (permalink)
    0
    quote:
    Originally posted by robk

    quote:
    Originally posted by Nightingale

    Very nice car rob, I assume you are the one I met up with the other day to talk about the adaptronic? :) Your car looks very nice.



    You must be Jeff right!?




    Yep, very nice car you have there. Bring it down for a meet sometime and meet some great ppl. :)
    #7
    DVST8R
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    RE: robk's MR2 Turbo 2009/12/17 11:40:24 (permalink)
    0
    Nice, the black ones go faster
    #8
    jezza_boii
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    RE: robk's MR2 Turbo 2009/12/17 13:11:24 (permalink)
    0
    Looks perfect
    #9
    robk
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    RE: robk's MR2 Turbo 2009/12/17 13:19:57 (permalink)
    0
    EDIT:
    Note to future readers...remember that these posts are very old and the car has changed a lot since then, including the rims.
    post edited by robk - 2014/06/19 13:09:00
    #10
    kameleon
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    RE: robk's MR2 Turbo 2009/12/17 18:23:40 (permalink)
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    they're "Autopista" side skirts. car is nice and clean:)
    #11
    surok
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    RE: robk's MR2 Turbo 2009/12/17 19:45:30 (permalink)
    +1 (1)
    looks really good, i look forward to having a closer looksie at the January meet
    #12
    B24
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    RE: robk's MR2 Turbo 2009/12/18 08:58:04 (permalink)
    0
    That is a great piece of kit robk.
    Did the wilwood set up come with the car or did you source that mod?
    #13
    robk
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    RE: robk's MR2 Turbo 2009/12/18 11:39:10 (permalink)
    0
    *EDIT*: There were Wilwood front brakes on the car when I bought it, but they have since been removed and replaced with a different brake upgrade.
    post edited by robk - 2014/06/18 14:15:17
    #14
    Nightingale
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    RE: robk's MR2 Turbo 2009/12/19 16:49:48 (permalink)
    0
    Do you know what type of brake pads you are using?
    #15
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