Author Topic: Charles' Gen-4 Swapped MR2  (Read 19607 times)

September 20, 2012, 09:44 PM #0

charlesjm Offline

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The car is a 1991 MR2 Turbo with a JDM Gen 4 3S-GTE, from a ST-215 Caldina.
The colour is the factory Steel Mist Grey; T-Top with manual steering (factory) and manual transmission (of course).
Bought it off autotrader.com for 4grand, shipped it up from California.

In the summer of 2012 my USDM Gen 2 3S-GTE (engine that came with the car) detonated and cracked the ring lands on three pistons. After looking into rebuilding the Gen 2, swapping a Gen 3 3S or a V6 into it, I decided to swap the Gen 4 JDM 3S-GTE into the car.
I chose the Gen 4 because the engines were made from 1998-2002 and were never seen in the MR2. The Gen 4 featured coil pack ignition (vs. a distributor), MAP sensor (Gen 2 had MAF), many many less vacuum lines (thank god, Gen 2 was a rats nest), but most notably more power.

A USDM Gen 2 3S-GTE is rated to have 200hp.
A JDM Gen 3 is rated to have 250.
The JDM spec Gen 4: 265.

The Gen 4 has a different turbo, head, intake manifold, cams, fuel rail, injectors, ECU, different crank, rods and pistons, a higher compression ratio and thicker cylinder walls than the Gen 2.

The mods list:
   -Engine:
      -Kept stock
      -Stock JDM CT15b
      -Stock Gen4 boost control system (15PSi)
      -Tial Q 50mm BOV
      -Greddy side mount intercooler
      -Custom Mandrel bent intercooler piping
      -KO Racing mirror polished dual fan engine lid shroud
      -Walbro 255 fuel pump
      -F1 Racing chromoly Flywheel
   -Exhaust
      -Blitz NurSpec 3inch catback
      -Factory downpipe with hollowed catalytic converter
   -Transmission
      -Rebuilt Transmission (orginal MR2 trans, not the JDM Caldina trans)
      -Brass shifter bushings
      -F1 Racing Stage 2 Clutch
   -Interior
      -Prosport Boost Gauge
      -Prosport Fuel Pressure Gauge
      -Prosport Oil Pressure Gauge
      -Innovate A/F Ratio Gauge
      -Dual Pillar Gauge Mount
      -EMS Powered Dual Ashtray Gauge Mount
      -Blitz Turbo Timer
      -TRD Short Throw Shifter
      -Corbeau C4 Racing Seats w/ modified factory seat rails
      -Alpine Touchscreen Deck
      -Nardi Deep Corn 350mm Steering Wheel
      -NRG Hub
      -Relocated Cruise Control
      -LED Dash Lights
      -Tinted Windows + T-tops
   -Wheels:
      -OLD: 17" Sportmax XXR 962, Gunmetal finish, with machined 3" lip (rear)
      -NEW: Advan Racing RGII 17x8+37 17x9+35, installing in spring
      -Tires: Front TBD 235/40, Rear Federal 959RSR in 255/40
      -Blue finished Lugnuts
      -Slotted/Vented Rotors
      -8mm Spacer (Front)
   -Suspension
      -Tokiko Adjustable Shock Absorbers
      -Tein S-Tech Lowering Springs
   -Exterior
      -Shine Auto S-Type Front Lip
      -Shine Auto Carbon Fiber Rear Add-ons and Lower Center Piece
      -1994+ OEM MR2 Taillights w/ JDM amber corners
      -Custom LED reverse lights
      -Carbon fiber vinyl wrapped tail light center piece
      -EZ Lip Side Skirt Extensions
      -Clear Front Corner Lights
      -Home Made License Plate Mount
      -Custom "Gen-4 Twin Cam turbo" Side Decals


 
Last Edit: March 05, 2016, 02:47 PM by charlesjm
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    Charles' Gen-4 Swapped MR2
    « on: September 20, 2012, 09:44 PM »

    September 20, 2012, 09:44 PM #1

    charlesjm Offline

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    IMG_1472 by Charles Murray, on Flickr

    IMG_1488 by Charles Murray, on Flickr

    IMG_1441 by Charles Murray, on Flickr

    IMG_1491 by Charles Murray, on Flickr




    Last Edit: May 14, 2015, 05:58 PM by charlesjm
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      September 20, 2012, 09:55 PM #2

      Shaun Offline

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      September 20, 2012, 09:59 PM #3

      CFMP RAblue Offline

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      Very clean and nice ;)

      Did you do all the mods or did it come with some done?
      "Go Fast, Stop Fast"
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        September 20, 2012, 10:25 PM #4

        Riley Offline

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        Love your car!
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          September 20, 2012, 10:44 PM #5

          charlesjm Offline

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          Originally posted by CFMP RAblue
          Very clean and nice ;)

          Did you do all the mods or did it come with some done?
          The car came with most of the mods (bought for 4 grand on autotrader!), however the engine wasn't running properly, and the digital air/fuel corrector wasn't working properly either, so it took a good amount of work to get the car to where she was.
          Anwyays, the mods that pops and I have done since i've owned the car are:
          -Air/Fuel Ratio Guage
          -Tein S-Tech Lowering Springs
          -F1 Racing Stage 2 Clutch
          -F1 Racing Chromoly Lightened Flywheel
          -KO Racing Deck lid Fans
          -Slotted/Vented Rotors
          -Corbeau C4 Racing Seats

          Then in the winter we pulled the engine, stripped her right down and replaced every gasket. Also:
          Rebuilt CT-26 Turbo
          Refinished head (shaved by 6 thousandths of an inch)
          Rebuilt Transmission (Stock)
          "Custom" high flow cat (hollowed)

          The pictures are just loading on photobucket, will be posting more shortly
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            September 20, 2012, 10:48 PM #6

            Igor Offline

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            Very nice!
            Last Edit: September 20, 2012, 11:14 PM by IgorCabrilo
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              September 20, 2012, 10:51 PM #7

              Faken Offline

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              <3. Beautiful car.
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              [Mar 26 13:45:26] Igor:hearts before parts

                September 20, 2012, 11:03 PM #8

                charlesjm Offline

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                I'll put up pics from the winter rebuild tomorrow. Warning: it ain't pretty.
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                  September 21, 2012, 12:33 AM #9

                  CFMP RAblue Offline

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                  Thats some decent amount of work, not alot of ppl would of bought that car when it wasnt running properly... props ;)
                  "Go Fast, Stop Fast"
                  Extreme Stop Slotted/Drilled Rotors
                  KVR Performance Slotted Rotors
                  Magnaflow CBE

                    September 21, 2012, 07:55 AM #10

                    EK Hatch Offline

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                    I've seen this up around my place. Very nice.
                    "Low 'N Slow"

                      September 21, 2012, 08:14 AM #11

                      91Atrac Offline

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                      Nice mr2! Love the cars not to mention same motor as I ;) did you rebuild the turbo yourself or did western turbo do it for you?
                      91 Celica Alltrac

                        September 21, 2012, 09:42 AM #12

                        Sahba Offline

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                        Very nice ... how much?

                        /Borat

                          September 21, 2012, 11:24 AM #13

                          charlesjm Offline

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                          • charlesjm barely matters.charlesjm barely matters.
                          Originally posted by 91Atrac
                          Nice mr2! Love the cars not to mention same motor as I ;) did you rebuild the turbo yourself or did western turbo do it for you?
                          Western Turbo ofcorse, haha. 3S-GTE love!
                          #KenDeals
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                            September 21, 2012, 12:01 PM #14

                            charlesjm Offline

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                            • charlesjm barely matters.charlesjm barely matters.
                            The Gen2 mods list:
                               -Engine:
                                  -Blitz 750 Injectors
                                  -Magnacor Spark Plug Wires
                                  -K&N Pod Filter
                                  -Apexi Fuel Management System
                                  -Every gasket in the engine replaced as of winter 2011 / spring 2012
                                  -Refinished head (shaved by 6 thousandths of an inch)
                                  -KO Racing Deck lid Fans
                               -Turbo
                                  -Stock CT26 turbo (Rebuilt by Western Turbo)
                                  -AEM TruBoost boost guage/controller
                                  -HKS SSQV BOV
                                  -Greddy Intercooler
                                  -Greddy Turbo Hard Piping
                               -Exhaust
                                  -Blitz NurSpec 3inch catback
                                  -Hollowed Catalytic converter
                               -Transmission
                                  -Rebuilt Transmission (stock)
                                  -Brass shifter bushings
                                  -F1 Racing Stage 2 Clutch
                                  -F1 Racing Chromoly Flywheel
                               -Interior
                                  -AEM True Boost Controller/Gauge
                                  -Innovate A/F Ratio Gauge
                                  -Blitz Turbo Timer
                                  -TRD Short Throw Shifter
                                  -Corbeau C4 Racing Seats
                                  -Alpine Touchscreen / Nav / Bluetooth deck
                               -Wheels:
                                  -17" Sportmax XXR 962, Gunmetal finish, with machined 3" lip (rear)
                                  -Dunlop Tires
                                  -Slotted/Vented Rotors
                               -Suspension
                                  -Aftermarket Adjustable Struts
                                  -Tein S-Tech Lowering Springs
                                  -New bushings as of spring 2012

                            Every part (minus pistons, connecting rods, crank) taken off, cleaned and painted (and engine bay, subframe, intercooler, heat shields...) during the 2011/2012 winter rebuild.

                            Winter 2012 Rebuild:

                            So, pops and did a winter rebuild last year. The engine had oil coming from everywhere, we decided to replace every seal and most of the hoses. We knew that it was a pretty freaking large job, but what we didnt account for was the time cleaning the oil off all the parts.
                            This is what we started with:

                            Step 1: pull motor

                            Turbo before:

                            Turbo after:

                            General pics:





                            Block painted blaaaaaaack

                            The head, pressure checked and shaved 6thou of an inch

                            Things comin back together

                            The custom "high flow" cat

                            We did it! *drool*

                            Finally going back in the car

                            The day we got the deck lid fans installed:

                            First test cruise

                            My favotire picture from highschool. (note: still didnt have the front trim/lip on the MR2, thats why it looks funny)

                            Got 2000 very happy miles, then disaster struck; oil out the blowoff.


                            The car began to idle roughly and was misfiring, in addition to the oil spraying from the blowoff. I figured a seal went in the turbo, hence the oil shooting out, and something was up with ignition (either with the distributer, or fouled a pulg).
                            I was wrong.
                            Compression test confirmed the worst, low compression on cylinders 2 3 and 4. Rings were done. Heartbreaking. Especially since i told my dad i wanted to do the rings, but he said we wouldnt need to.
                            So here we are: the car on a trailer:


                            Short for cash, and it needs a rebuild. So my season with the MR2 is done.

                            Plan for next spring:
                            Pull the engine again, strip her right down, get the block bored out slightly, get upsized forged internals, then throw it all back together.
                            See you all next year!
                            Last Edit: September 10, 2013, 03:44 PM by charlesjm
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                              September 21, 2012, 12:23 PM #15

                              91Atrac Offline

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                              3sgte love ftw! That sucks I hear the motor went again :/ I've got low compression in cylinder 2 right now and a ton of other problems. Just waiting for it to die lol. Follow me and the goodies I'm throwing into the Alltrac. Winter will be delightful :)

                              You should do a kind of stroker build by using a 5s bottom end and 3s top end. You also going to delete the tvis system? Or do the mr2's not have that.

                              Beautifully done car tho. The bay looks awesome and the fan shroud/hood looks amazing. What did it weigh with the shroud cuz that hood is light!
                              91 Celica Alltrac

                                September 23, 2012, 09:29 AM #16

                                charlesjm Offline

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                                Originally posted by 91Atrac
                                3sgte love ftw! That sucks I hear the motor went again :/ I've got low compression in cylinder 2 right now and a ton of other problems. Just waiting for it to die lol. Follow me and the goodies I'm throwing into the Alltrac. Winter will be delightful :)

                                You should do a kind of stroker build by using a 5s bottom end and 3s top end. You also going to delete the tvis system? Or do the mr2's not have that.

                                Beautifully done car tho. The bay looks awesome and the fan shroud/hood looks amazing. What did it weigh with the shroud cuz that hood is light!

                                I'm not to sure about what I'm gonna do with the bottom end yet. I've heard of guys doing the 5s bottom end swap, but those are the 2's that are pushing like 500 :P I want like 300, maybe more  :banana:
                                The TVIS actually wasn't working, as we discovered during the winter rebuild. We did some DIY magic cause toyota wanted a small fortune for a new TVIS system. So no, I still have it. Any benefits to getting rid of it?
                                Yeah, i love the shroud. It's still light
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                                  September 23, 2012, 10:42 AM #17

                                  91Atrac Offline

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                                  Well I've had some ppl swear by the torque curve it gives when it's working properly and for us being our goals at 3-350 it almost better to leave it if its working! Since yours isn't tho I'd delete it. If you haven't blocked it properly you might actually be losing power from the butterflies not opening the closed runners after the 4200rpm it opens at.

                                  So really not a huge difference if its deleted as long as the butterflies are open all the time.
                                  91 Celica Alltrac

                                    September 23, 2012, 01:18 PM #18

                                    furmuncher Offline

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                                    sexy deuce, glad to see another 1 in the family

                                    www.mr2oc.com  for all your mr2 , 3gste questions...alot of great info and helpful guys on there.
                                    " look , i can count to crayon "
                                     
                                    Understeer is when you hit the wall with the front of the car and oversteer is when you hit the wall with the rear of the car.
                                     
                                    Horsepower is how fast you hit the wall, torque is how far you take the wall with you.

                                      September 23, 2012, 01:21 PM #19

                                      furmuncher Offline

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                                      hey if your interested i have a border carbon fibre hood that has been painted to match my car im not using.it is drilled for hood pins as well. i would let it go cheap if your looking for a mod before the paint shop :)
                                      " look , i can count to crayon "
                                       
                                      Understeer is when you hit the wall with the front of the car and oversteer is when you hit the wall with the rear of the car.
                                       
                                      Horsepower is how fast you hit the wall, torque is how far you take the wall with you.

                                        September 23, 2012, 01:40 PM #20

                                        kiraamzsy Offline

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                                        Looking good.



                                          September 23, 2012, 02:51 PM #21

                                          caboose36 Offline

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                                          Do you live around Birds Hill? I remember about a year or so ago I was at the Sobeys in Birds Hill with my Grandmother. When we came out of the store there was a SMG Mr2 there waiting, and I had a chat with the owner. That wouldnt have been you, or was it? I have a black '92 RHD Turbo.

                                            September 23, 2012, 02:51 PM #22

                                            JayPe3 Offline

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                                            Awesoem, good stuff man.

                                              September 23, 2012, 06:52 PM #23

                                              charlesjm Offline

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                                              • charlesjm barely matters.charlesjm barely matters.
                                              Originally posted by caboose36
                                              Do you live around Birds Hill? I remember about a year or so ago I was at the Sobeys in Birds Hill with my Grandmother. When we came out of the store there was a SMG Mr2 there waiting, and I had a chat with the owner. That wouldnt have been you, or was it? I have a black '92 RHD Turbo.

                                              That would be me. The cars changed quite abit since then...
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                                                September 23, 2012, 06:53 PM #24

                                                charlesjm Offline

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                                                • charlesjm barely matters.charlesjm barely matters.
                                                Originally posted by furmuncher
                                                hey if your interested i have a border carbon fibre hood that has been painted to match my car im not using.it is drilled for hood pins as well. i would let it go cheap if your looking for a mod before the paint shop :)

                                                Have any pictures? Won't hit the paint shop till probably NEXT winter or later... so abit yet. And im slightly broke.
                                                I personally wouldnt run hood pins on my car, going for that cleeeeeean look
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                                                  Charles' MR2 Turbo
                                                  « Reply #24 on: September 23, 2012, 06:53 PM »