Supercharged 2GR SW20 Project

[lasersooby]

Decided to add meth injection to the intake air before the air went through the supercharger and through the plate w2a intercooler.

Purchased 2 x 2000cc Bosch Top Feed Injectors for the job. The plan is that we will set everything up to run but the meth injection will be sorted after the engine is up and running but before we get it on to the dyno. The controller for these injectors will be through the UniChip piggyback ECU:

[lasersooby]

Received a few images of my engine block and parts from CSL Race Engines that we agreed on getting done.

Pretty excited and the following was done to the engine block and heads:

1. Block bored out to suit 94.25mm forged pistons that were purchased off MWR
2. Rotating assembly was fully balanced
3. Crankshaft was lightened and shaped
4. Machine deck block faces
5. Make block spacers
6. Machine cylinder head faces
7. Machine valve seats - custom 3D cutters
8. Machine valve front & back faces
9. Machine top valves inlet - 0.25mm, exhaust 0.4mm
10. Dummy assembly to check deck height
11. Head already been ported and polished, port matched to exhaust as well as lower intake manifold
12. Lower intake manifold ported and polished for maximum flow from the supercharger
13. All parts were acid dipped then vapor blasted to clean prior to the work being carried out

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[lasersooby]

Just a few more pictures of the rotating parts getting fully balanced. Do not worry, the green paint on the flywheel will be removed before it gets installed:

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Engine block details and the clearance on the main bearings. These clearances are from the factory:

Different angles of the block, needs a heap of cleaning before we start the assembly process. Everything on the engine has been vapour blasted:

[lasersooby]

Interesting conversation with the Manawatu Toyota guys, especially Mark Ireland who sorted out the main bearings for the engine build.

To pick the bearing, we had to get the bearing clearances that were already stamped on the underside of block and also the front of the crank. See images below:
Block:

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Crankshaft:

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Based off the readings off here, this is the Table to use to determine the correct main bearings for the engine:

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For anyone that wants a bit more detail on what is what, here is a link to the PDF file out of the service manual for the 2GR Aurion:

2022Feb10-PDF File to Determine Bearing Size.pdf

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[lasersooby]

Pulled the pin and ordered a carbon fibre vented bonnet for the project. Buying one on its own was going to cost nearly NZ$2,000. Thankfully a number of friends (actually 3), stepped up to order with me and we have managed to get a really good price on this set, the savings all come from the shipping.

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Shipping crate:

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Invoice:

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[lasersooby]

Mark Ireland from Manawatu Toyota came through with my order of the OEM Main Bearings, big ups to Mark.

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[lasersooby]

It has been a while since I posted, turns in life has a funny way of getting into the mix which stops us from doing things that we enjoy.

Anyhow, I purchased Extended Boot Lock Key Set from MR2 Heaven with a few other parts. Richard was amazing to deal with and nothing was a problem, he even organized cheaper shipping options for me which saved a bit of coin. The link for this part is:

https://mr2heaven.com/collections/exter ... i-94-locks

Great quality part and fits without any issues (have to now install the centre panel once it is painted:

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[lasersooby]

Managed to get the radiator fan switch installed in the alloy radiator as well:

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[BillyM]

Hi Mo,
My name is Billy Mitchell living in the Nelson area, may I contact you to discuss the Wilhelm Geometry Suspension Kit, which I have also just purchased.
Thanks,
Billy Mitchell
[email protected]
mob 0211557553

[lasersooby]

Hi Billy, I've just sent you a text message.

Chat tomorrow, thanks

[lasersooby]

Had to take time out to clear my head after my mum's death on Friday in Melbourne and what better way to do this than to start preparing the engine assembly. The first step was buy a new engine stand as well as an engine lifter from Supercheap (could not afford Ripco prices ).
Most of the parts laid and will start on this next week once I return from Melbourne.

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[lasersooby]

Things are getting closer and closer to getting the engine bay items sorted and one of the items left to do was the Oil Cooler kit that i purchased from Wilhelm Raceworks. Alex was incredibly helpful and even sourced the fittings & hose for the kit to help with the build.

Boxed items:

We made a mounting plate for the Mishimoto In-Line Oil Thermostat. the plate basically mounts on the firewall between the engine bay and the cabin and another plate then sits on the inside to provide the support for the mounting.

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Little helper doing a bit of work to get the plates mounted

Stainless steel mounting plate sorted and ready for the next phase:

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Mishimoto In-Line Oil Thermostat:

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Vibrant -10 AN fittings added to the thermostat:

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In-Line Oil Thermostat mounted to the plate that we installed earlier:

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Fitted -10AN 90degree fittings onto the Oil Cooler:

Vibrant braided push lock hoses measured and cut before installing the fittings:

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The oil cooler had to be removed several times from its location to get access to the ports because there is not enough space between the body and the cooler once it is mounted in place. No biggie, just need a bit of patience to do this (very snug fit):

[lasersooby]

Connected the hoses up to the Thermostat:

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Completed views:

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If anyone wishes to order any of these fittings and hoses, there are the details for them (pictures):

[lasersooby]

Cleaned and greased up all the working mechanisms for the right hand door and installed everything in the door. Very happy with the outcome.

Internals in the door:

Outer door moulding:

Door Mirror Bracketl:

Door weatherstrip:

Plastic cover:

[lasersooby]

After a bit of false start (purchased Hux Racing E153 Hybrid Gear Shifter) to run with my EA60 6speed box, we decided to pull the trigger and go with buying the Lotus Evora gear shifter that is made specifically to fit this gearbox. The layout for the shifter and cables in Lotus, see bleow:

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Gear Shifter & Schematic (Parts List):

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Purchased parts from SJS Parts in UK who are the Lotus agents. Great Team to deal with and very helpful throughout the process, parts shipped via DHL:

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The gear shifter is a work of art, has the reverse lockout as part of the shifter:

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All the other small pieces that I need to fit between the shifter and on the gearbox to make this work in the MR2:

Sadly, they did not have the long cable and had only the short one which they supplied. I am chasing up another supplier in UK for the long cable: