Supercharged 2GR SW20 Project

[lasersooby]

Ordered parts from Wilhelm Raceworks arrived containing oil cooler, oil cooler mounting plate, hoses and all the fittings that goes with it install the kit.

[lasersooby]

Getting things ready for the front mount water to air cooler installation. This is to support the plate intercooler that is being done by Elate Manufacturing:

2021Jul31-Pix01.JPG (85.95 KiB) Viewed 1968 times

We removed the tow hook from the front crash bar so that we could mount the w2a intercooler:

Prepped the exposed areas and painted:

Mock fit to get all the measurements in so that we know exactly where we were going to mount the w2a intercooler:

Getting the mounting brackets welded to the intercooler by Dylan, alloy welding

Mocked up then installed the cooling fans:

The front intercooler in place bolted up to the crash bar, still have to clean up the foam crash pad:

I will grab the front bumper from my Painter tomorrow and test fit that to see what mods we have to make to that before he paints the bumper

[lasersooby]

Box arrived from DeRoure UK containing clutch parts from the Lotus Evora (the Evora runs the supercharged 2GR with the EA60 gearbox, which is the same setup as what I am trying to replicate in the MR2)

Release Bearing Clip (EA60 gearbox has cast fork):

Release Bearing Adapter (Lotus uses a sandwich plate to mount the gearbox to the engine because the EA60 normally comes mated to the diesel NA and Turbo diesel 4 cylinder engines). This adapter makes up for the gap that the sandwich plate creates. 2GRs on the Lotus also have dual mass flywheels which are pretty chunky. I am not using a sandwich plate and going with the Fidanza flywheel which is thinner than the dual mass OEM flywheel. This then creates that gap again making the need to use this adapter:

Release Bearing:

Using the Wilwood Big Brake Kit means, I cannot use the OEM dust shields which have the air vents built into them to help cooling. Some very clever people around the world have found out that Porsche (yep, you read it right) have special spoilers for their brake cooling on the GT3s and these will fit the MR2 without any issues and do a great job as well. Please buy these parts if you are going to use them from an overseas supplier, Porsche NZ want your both legs, both arms and something else if you were to buy from them:

[lasersooby]

Received a couple more pictures from Travis at Elate Manufacturing. It is coming along nicely, should be on its way to me soon:

[lasersooby]

TCS Motorsports (Ty Saxon) produce a range of parts for MR2s and they guys are really awesome to deal with, received my package from them:

Bolt on kits for the coolant hose for the 2GR in the SW20 chassis which removes the need for the hardline pipe for both the heater and the radiator and other make shift hoses that you need to make when doing this swap:

https://www.tcsmotorsports.com/collecti ... fe-v6-swap

The other kit is for the AC system, incorporates the SW20 AC lines that run under the body to the 1GR compressor that we will be using on the 2GR. The orientation for the fittings is already incorporated into the design which makes life a whole lot easier:

https://www.tcsmotorsports.com/collecti ... 9304069229

Added bonus in the box, couple of packs of candy

[huddfan]

Box arrived from DeRoure UK containing clutch parts from the Lotus Evora (the Evora runs the supercharged 2GR with the EA60 gearbox, which is the same setup as what I am trying to replicate in the MR2)
2021Aug11-Pix01.jpg2021Aug11-Pix04.jpg

Release Bearing Clip (EA60 gearbox has cast fork):
2021Aug11-Pix05.jpg

Release Bearing Adapter (Lotus uses a sandwich plate to mount the gearbox to the engine because the EA60 normally comes mated to the diesel NA and Turbo diesel 4 cylinder engines). This adapter makes up for the gap that the sandwich plate creates. 2GRs on the Lotus also have dual mass flywheels which are pretty chunky. I am not using a sandwich plate and going with the Fidanza flywheel which is thinner than the dual mass OEM flywheel. This then creates that gap again making the need to use this adapter:
2021Aug11-Pix06.jpg2021Aug11-Pix07.jpg2021Aug11-Pix08.jpg

Release Bearing:
2021Aug11-Pix09.jpg2021Aug11-Pix10.jpg2021Aug11-Pix11.jpg2021Aug11-Pix12.jpg

Using the Wilwood Big Brake Kit means, I cannot use the OEM dust shields which have the air vents built into them to help cooling. Some very clever people around the world have found out that Porsche (yep, you read it right) have special spoilers for their brake cooling on the GT3s and these will fit the MR2 without any issues and do a great job as well. Please buy these parts if you are going to use them from an overseas supplier, Porsche NZ want your both legs, both arms and something else if you were to buy from them:
2021Aug11-Pix13.jpg2021Aug11-Pix14.jpg

Do you mind sharing the part numbers for the release bearing, clip, and adapter? I'm planning on using a EA60 with my 2GR.

Cheers!

[lasersooby]

Box arrived from DeRoure UK containing clutch parts from the Lotus Evora (the Evora runs the supercharged 2GR with the EA60 gearbox, which is the same setup as what I am trying to replicate in the MR2)
2021Aug11-Pix01.jpg2021Aug11-Pix04.jpg

Release Bearing Clip (EA60 gearbox has cast fork):
2021Aug11-Pix05.jpg

Release Bearing Adapter (Lotus uses a sandwich plate to mount the gearbox to the engine because the EA60 normally comes mated to the diesel NA and Turbo diesel 4 cylinder engines). This adapter makes up for the gap that the sandwich plate creates. 2GRs on the Lotus also have dual mass flywheels which are pretty chunky. I am not using a sandwich plate and going with the Fidanza flywheel which is thinner than the dual mass OEM flywheel. This then creates that gap again making the need to use this adapter:
2021Aug11-Pix06.jpg2021Aug11-Pix07.jpg2021Aug11-Pix08.jpg

Release Bearing:
2021Aug11-Pix09.jpg2021Aug11-Pix10.jpg2021Aug11-Pix11.jpg2021Aug11-Pix12.jpg

Using the Wilwood Big Brake Kit means, I cannot use the OEM dust shields which have the air vents built into them to help cooling. Some very clever people around the world have found out that Porsche (yep, you read it right) have special spoilers for their brake cooling on the GT3s and these will fit the MR2 without any issues and do a great job as well. Please buy these parts if you are going to use them from an overseas supplier, Porsche NZ want your both legs, both arms and something else if you were to buy from them:
2021Aug11-Pix13.jpg2021Aug11-Pix14.jpg

Do you mind sharing the part numbers for the release bearing, clip, and adapter? I'm planning on using a EA60 with my 2GR.

Cheers!

Hi mate,

No problems, here are the part numbers and links as well:

Release Bearing - A132Q6007S: https://www.deroure.com/partinfo.asp?MA ... ID=1094966

Adapter - A132F0014F: https://www.deroure.com/partinfo.asp?MA ... ID=1094964

Spring Clip - A132Q6008S: https://www.deroure.com/partinfo.asp?MA ... ID=1094967

My suggestion is not to purchase the spring clip as the release bearing came with a clip. I did not know this when I purchased the parts.

The Team at DeRoure were really good in getting this processed quickly and shipped to New Zealand.

Good luck and keep us informed as to how you are getting on with your project as well

[lasersooby]

For my application to run with the EA60 6-speed gearbox, was advised by Paul Woods to purchase an Exedy Stage 1 Clutch Kit that is suitable for the Turbo MR2

Could not find anything available in NZ and also some of the suppliers that could bring this kit in, was going to cost me over $1,300.00. Managed find the kit through Rockauto US. I highly recommend people to deal with them, they are a professional outfit and their pricing is just out of this world.

Shipped for this kit was only about US$50.00 via FedEx.

This is the kit on Rockauto website:
https://www.rockauto.com/en/parts/exedy ... h+kit,1993

The details of the kit is here:
https://www.rockauto.com/en/moreinfo.ph ... 80&jsn=271

Box received this morning:

Contents:

Instructions:

Ultra Fibre Disc:

Release Bearing & Clip (not suitable for my application) and Spigot Bearing:

Clutch cover, has 40% more clamping force than OEM, suitable for my high torque application:

Grease and ID Tag of the Clutch Cover:

[lasersooby]

Just to be sure that the clutch plate fits the gearbox input shaft, I thought I had better do a test fit. Thankfully it does fit:

This is a comparison (side by side) between the Exedy supplied MR2 Turbo Release Bearing vs the Lotus Evora Release Bearing and the Adapter that we need to run the 6-speed box with the 2GR:

The Lotus Evora Bearing & Adapter:

Adapter mated to the Release Bearing, just a test fit as it needs to be pressed in properly, has a nice interference fit:

[GDII]

It's interesting to see the Exedy bearing being a lot thinner than the Lotus part. Also a lot thinner than a Toyota supplied bearing. The Toyota one goes all the way up to the pressure plate contact ring. A very small gap unlike this one. If it was as thick as the Lotus one it would be right. But your setup is different anyway but it's good to see a comparison. Always use the OEM Toyota supplied bearing where possible. This is why.

[lasersooby]

Received my package from Elate. Travis Peek is the man at Elate, he owns the Business is an awesome individual to deal with. I went to him with a concept as I saw that his Business produced intercoolers for the supercharged V6 Commodore and I wondered if something similar could be made for the TRD or the Lotus supercharged 2GR (both engines and charger are the same, except that the later ones from Lotus use the TVS1900 which already has a cooler built in with the charger).
If any one wants to check out Elates website, here is the link: https://elatemfg.com/

Very nicely boxed up goodies delivered to my work:

The parts were also nicely bubble-wrapped inside the box:

Intercooler developed by Travis and his Business. The core fits snugly inside the housing. The top plate will be powdercoated the same colour as the core housing:

Bosch Pump to move the coolant around. Seriously think about using "waterless coolant - Evans" right throughout both my cooling systems:

Pump inlet and outlet measurement:

2021Sep05-Pix30.jpeg (46.38 KiB) Viewed 1786 times

Other fittings and fasteners. We will use AN fittings throughout:

Last but not least, the complimentary Elate key tag

[Swampy]

Nice to see your SW progressing along nicely Mo. I too love Rockauto, but agree with Phil about using oem parts. Rockauto have sent me different parts in the past. Usually one side being different from the other.

[lasersooby]

Nice to see your SW progressing along nicely Mo. I too love Rockauto, but agree with Phil about using oem parts. Rockauto have sent me different parts in the past. Usually one side being different from the other.

Thanks mate, appreciate the advice. The release bearing for my setup is coming from the Lotus setup OEM part so we should good there. It is interesting though that Exedy being a well known brand sells parts that are not as heavy duty as the OEM parts.

It would have been a pain to return the incorrect parts back to the US, hopefully it got sorted out for you mate.

[lasersooby]

Managed to get to Elite Automotive workshop today to do a quick test fitting of the plate intercooler so that we could provide Elate Manufacturing if the intercooler needed any mods. Thankfully everything went pretty well.

I will let you decide what it looks like and if you have any questions, fire away.

Plate Intercooler sitting on top of the lower intake manifold:

Getting the heads ready to test fit the block:

Heads on the block (do not mind the dirty block, is getting an acid wash soon):

Lower intake on the heads:

Plate intercooler on the manifold:

Adding cam covers to heads:

Finally, the supercharger sitting on top of the intercooler:

Block is off to CSL Cams & Engine Builders next week for machining so that we are able to fit the larger forged pistons. Block will be given an acid wash and also balancing of all the rotating parts with the clutch kit installed with the Fidanza flywheel

[GDII]

Still working on wiring things in the background. The engine harness is complete.

Today we setup the upgraded fuel pump and wiring on the stock tank hanger.

We decided to use the deutsch connector type for the new plugs. There are 3 typical sizes for these but more exist.
DTM. These carry 7.5AMPs and wire gauge from 14-22AWG.
DT. 13AMPs and 14-20AWG
DTP. 25AMPs and 10-14AWG
For this application as we expect the current draw on the pump to get close to 13AMP we decided the next step up for the plug to the DTP size.
Using a crimp tool specific to this type of closed barrel pin is this IWISS tool. It is adjustable from 14-26AWG which covers the range most automotive wiring uses.

To get upgraded power to the pump which comes with what looks like 14AWG wiring which can take a decent AMP draw you grab a pair of fuel tank bulkhead studs. Drill a 6mm hole for each. These have o rings to seal the hole.

Then you get some decent tinned copper eyelets for the wiring and crimp in place.

Then cover the ends with Raychem SCL heat shrink.

The repeat for the top.

Insert the DTP pin into the crimp tool and execute.

The wire used here is Millspec. We reused the sleeve from the original wiring outside the tank to keep the wires contained. Still in good condition. We also drilled out all the rivets of the old wiring to remove it. Capped the positive wire even though it is no longer connected. Just to tidy it up.

Insert into the plug body. Sorry I didn't get many photos of the process. Was just working away doing the job and forgot.

Pump is just mocked up for wiring purposes. We are sourcing a nitrile rubber pump sleeve to help reduce any potential noise this 340LPH @ 40psi pump could make. Why a 340lph over a 255lph? This is a supercharged V6 with potential for more power and E85 use. So best future proof now than have to take the smaller pump out. And because we are using this pump it has a higher AMP draw so the wiring upgrade seemed like the best idea while we in there. I'll be adding in a new relay that will get switched by the old pump power and new power taken from the battery.