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Pistols MR2 story.. *** I'm Back*** New car page 30
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craig




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PostPosted: Fri Sep 06, 2019 11:02 am    Post subject: Reply with quote Reply with quote including images

Top work as always fella [thumleft]
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pistol pete
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PostPosted: Wed Sep 11, 2019 6:05 am    Post subject: Reply with quote Reply with quote including images

So Dropped the Gearboxes off to Patrick Chambers. He is putting the gearset from the celica box into the MR2, so we keep the MR2 casing, linkages and Diff, but had the 190 engine gears to keep the car in lift.
i am not currently swapping over the longer 6th, as it is a track only car.

At home last night a jumped onto getting the engine ready.
First up was to change the manky sump for a baffled one. I am going for a 1zz sump for now and then later ill be adding an accusump when funds allow




Also fitted the new Blitz oil filter...



next up was lift bolts. these are know to snap or wear. so while i have it they are 80p each so might as well and change the cam cover gasket too





Onto the lower temp TRD thermostat



fitted following these instructions closely


New water pump while there too
old one had a plastic impeller


new is a metal impeller


new sparks fitted too






I did also swap the idler pulley from the 1zz to the 2zz which sits where the air con normally would. The idler bearings are knackered, so Patrick is ordering em a new on to pick up when i get the gearboxes back.

Tonight hopefully ill be able to tackle starting to swap the looms and generally getting it all back together
_________________
MR2 Sprint zombie outbreak response vehicle
https://www.facebook.com/pages/Zombie-Sprint-Page/1548040272127049
https://www.youtube.com/channel/UCNBrEdG4xcH5ds-qbox0FwQ
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pistol pete
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PostPosted: Sun Sep 15, 2019 10:54 pm    Post subject: Reply with quote Reply with quote including images

A bit more has happened

Got both the 1zz and 2zz out in the sunshine to transfer needed parts and start building up the 2zz

removed the injectors and fuel rail from the 1zz . resinstalled the 2zz injectors and 1zz fuel rail so the fuel feed is on the correct side
blocked up the required (or not as it may be) coolant lines.



Swapped over the coolant lines then reinstalled the 1zz wiring loom.





pulled the 2zz loom into the back room and removed teh 3 wires and 2 plugs required to make lift work.



Popped up to my mates to pick up my new exhaust.






It was very nicely wrappedn, a good job. but i cannot go near the stuff without itching like a mofo. so it had to come off.

nice exhaust under there.



The first silencer was rattling. so cut it open and removed the rattle.. the other two back boxes are able to be repacked, so i just left this one empty and see how it goes..



new plate welded back on


Lastly made a new mini loom for the oil and lift switch





also i thought id weigh in the civic R EP3
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pistol pete
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PostPosted: Mon Sep 16, 2019 9:55 pm    Post subject: Reply with quote Reply with quote including images

I'm on nights this week which always means i can get a bit done..
hoping to pick up the gearbox this week which may mean engine in at the weekend!!

so managed to get a bit done today..
first up was putting the lift cables into the loom.. i am pretty happy with the finished product,





my little helper kept throwing me her ball so i could chuck it for her.. this slowed me down. but how can you say no!


I got a little trick from a friend a few years back, i want to get some poly engine mounts in future. but i am currently on a tight budget to just get the thing running. So using his trick.. filled the old engine mounts with Stickaflex. this has stiffened them up a load.
Ill see how it is when on the car. if no good ill order new ones. but worth a try



The others decided to help at this point



With the engine just waiting to go into the car. i thought it was about time i actually did some work on the car itself to prep!
so i covered all front suspension in penetrating spray. ill leave that now and take apart tomorrow


next up into the car. again the helper is there


want to get rid of all the fan and heater unit


first bypassed the heater.


got it all out after some fighting


gave it all a tidy up, moved some of the loom, i can get this much tidier, as i am pretty sure there is loads i can just unplg and remove, but i am not doing this untill i know the engine is in and running (i don't want to add more potential faults in one go)


So then take a perfectly good dash


and attach with an angle grinder



test fit.. pretty pleased with how it looks.. was tempted not to run a dash at all but this just keeps it tidy for now




I know the photos are not the best, they were taken on my pad in a dim garage..

Last job before deciding i was tired after working last night.. As i am inside the car i wanted to get the harness and seat sorted..
So fitted eyelets for harness and wrapped on the harness bar




test fit.. very chuffed (this is my happy face)
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pistol pete
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PostPosted: Tue Sep 17, 2019 9:16 pm    Post subject: Reply with quote Reply with quote including images

only a little job today..
Nights.. makes me tired and grumpy sometimes.

made these last night




can't really see in the pic, but with better light i will get a pic.
raised the gearshifter by 6cm.



I will see what its like when engines in, but all seems okay a nicely placed at the mo
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pistol pete
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PostPosted: Mon Sep 23, 2019 5:53 pm    Post subject: Reply with quote Reply with quote including images

Updates coming thick and fast now!

First off i realised i have only gone and left the throttle cable bracket attached in the celica, which long ago went to the scrappy (who have already crushed it)
So Roger G is sorting me one at the weekend. so i shall carry on until then without it.

So first off
Went and collected my gearbox from Patrick Chambers.. ( i seem to be missing some pics is took. no idea where they've gone)
whilst there he added the bung for the first lambda to go in, rather than in the down pipe


As i am not running a cat, I got an Ebay spacer


I was then waiting for my clutch to arrive so got on with some little jobs

My Fan arrived for the dash, ths is just to see if it works, as a cheap try no harm!

the opening left in to vent air to the windscreen

cheap 12v fan


all dash and interior is back in.. but no pictures... Doh

next up i pulled this box that has been sat in the corner of my garage for ages



got them fitted up



Also this fun little package of ultra racing ARBs arrives


Also fitted a new pulley as the bearings had gone in the old one


My clutch arrived. so i went about fitting the clutch, and gearbox etc all back together, these are the pics i am missing. but it all went together nicely.
This is just before installation


I haven't gone to town making this engine a show shiney engine. t isn't worth the effort.. its going in a track/sprint car.. i am sure it will be in and out / replaced many times!

A while later.. magic happens and a 2zz is in the car!!!


Again missing a load of pics.. but got everything reconnected, Oil and gearbox oil filled, subframe back on, engine mounts on.etc etc etc
Then coolant filling. MR2s can be terrible for coolant bleeding.

this time I thought i would try a way I have not done before. I used a friends vacuum filler.
so it pulls all the air out of the system, collapses all hoses etc. you shut it off and leave it a couple seconds to see if you loose the vacuum. If you do you know there is a leak somewhere... i didn;t luckily.. well at the moment anyway..
Then put the filling line in a big bucket of new coolant and open the system up. it the draws and fills the system with coolant and no air...

Happy days




It is now almost ready to start.
I have modified the celica air box to fit, and i have "borrowed" some gasket material from work to make my own exhaust gaskets... so fingers crossed.. tomorrow i can turn the key!!!!!!
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pistol pete
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PostPosted: Tue Sep 24, 2019 5:42 pm    Post subject: Reply with quote Reply with quote including images

Big day today.
I borrowed some graphite sheet from work to make my own gaskets for the exhaust
I have always run these on my race/sprint track cars and never had one blow




Then worked on getting the exhaust in and mounted



Love the tail pipe!!




I had one hanger with nothing to hang on, luckily i had a spare Poly hanger so managed to get it like this which is holding it nice



I fitted up the rear ARB at this point to make sure nothing rubbed.. all was good.

Plugged in the Lambda sensors..some rerouting/cable adjustment required before putting bumpers etc back on

mocked up the inlet, butched the 1zz and 2zz intake piping. I need to get a bit of tubing to finalize it so i am happy..

but it was ready for a test start!

connected the battery checked everything over...
battery was dead..

charged it for an hour to give it some life that it could do the ignistion system, then jumped it off my civic battery

This is first start up..first turn of the key

https://www.youtube.com/watch?v=45QimL1stwU
I was pretty happy!

checked everything for leaks.. left it running till it got up to temp and fans kicked in. then turned off, as its in the garage no air for the fans to cool the rads.

heres a vid of once up to temp
https://www.youtube.com/watch?v=ctGHgufqx4g

ran well could not see any evidence of leaks anywhere.

there was an exhaust leak from the end of one the repackable boxes, so ill whip the end cap off and reseal it.

come to work today very happy..

next up is get the ARBs mounted and brakes suspension all bolted together. (tomorrows job)
then swap the ECU's and repin to match.
the try again see if it runs. if not i know its something in the wiring


thanks for all the comments guys
fingers a crossed for a trackday in october and a sprint in november
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pistol pete
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PostPosted: Wed Sep 25, 2019 7:43 pm    Post subject: Reply with quote Reply with quote including images

no Huge update today
had to do the school run and go to work early..
but managed to get couple bits done.. first was the number plate lights on the trailer.. swapped out..
then the tow car/now daily shogun has a parrot system in it which i hate. and when using bluetooth it would distort..
Pulled it all apart and found this rats nest in there!!



Found a couple loose connections, also a bent pin in one of the plugs.. then taped and tidied everything and mounted the blue box nicely behind the dash rather than let it rattle around
all back together


beast


anyways.. jumped into the garage. got the rear ARB in place again as it was upside down, swapped over. Fitted new drop links, and camber bolts.. all together apart from the brakes now.. (yes the discs cover rust pile needs to come off)


Got both rears done.
I moved to the front got the front ARB mounted, after having two bolts snap and having to drill them out in the worst place ever to get a drill in!! and got new drop links fitted, unfortunately no pics.

that'll be it till next week i expect. I am work early tomorrow, funeral on friday (BOO ), then off to blyton park Saturday/Sunday for race day in the RX8!!! woohoo So more work on Monday
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pistol pete
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PostPosted: Mon Oct 14, 2019 1:38 pm    Post subject: Reply with quote Reply with quote including images

Update time!!

I went away for a week for work, whilst i was away i made a list of all the little bits left.
As we all know the last 5% takes the most time. its all the fiddly stuff
Here was the list

60mm intake pipe (measure)
Finish air box
Bleed brakes
Extend lambda wiring
Mount lambda plugs
Secure carbon canister valve
Re pin ecu and mount celica key and transponder
Tyres on wheels
Alignment
Refit rear lights and bumper.
Tow hook.
Oil filter change
Compression test
Decal kit
Tighten steering wheel attach face plate
Wire in fan for windscreen
Mount go pro


I got home early on Thursday so manage to hit on with the jobs, managing to start to tick them off pretty quickly
Unfortunately as i was rattling though i did not take loads of pictures..

Of all of them i was most worried about was the Re pinning of the Ecu for the 2zz ecu, I didn't want to damage any ECU plugs.
But after reading all the guides and a few you tube vids, i started. after about an hour of head scratching and moving around, and a phone call to Patrick chambers it was done.
I then held my breath as i turned the key.. It fired straight into life.. big sigh of relief!!

I done a compression test for my own peace of mind..
It was good results all round





Bled all the breaks, done all the little jobs.. got the lights and bumper back one.. wheels back on.
got the car outside



here is the car sat running
https://www.youtube.com/watch?v=hEgk7-SqFX0

then it was loaded on the trailer


taken up to local alignment place. done to my investigations settings..
not all corner weighted yet, that will be later then i have done all the polybushing
But it does sit level. When all arms are done i will take it up to fensport get it set nicely.



Also got the tyres mounted so the car is currently sitting on the uniroyal rain sport 3s, and here are the Soft Avon ZZrs




Couple little jobs i had on the list.. was the intake link pipe, was using a temporary red silicon hose. i have found some tube at work and just need to re fit



also the carbon canister was rubbing on the dipstick, so some slight alteration to the canistor bracket


Just means i can move it by 1/2 inch will be enough..


Next came up on how i was going to actually test the car.
It was going to be book a brands hatch track day this week and get there and see how it goes, my big worry was i would do one lap and inevitably it something would break and the day would be lost.
It was still the best option until i phoned AIB insurance. They managed to sort me insurance on the car with all mods declared (basically a race car) and 1000 miles a year, for £200 which was same cost of the track day. but this covered me where i could drive up road (sensibly as its on road!!) but i could make sure the car runs all okay before going to track and driving it properly..
So fingers crossed one eve this week i can have a little drive in it!!!

It does have a small coolant leak, or the coolant is settling as i haven't seen any evidence of a leak yaet, so need to investigate that properly



Watch this space


As for the list of jobs above

60mm intake pipe (measure) Made, to fit tonight
Finish air box DONE
Bleed brakes DONE
Extend lambda wiring DONE
Mount lambda plugs DONE
Secure carbon canister valve DONE
Re pin ecu and mount celica key and transponder DONE
Tyres on wheels DONE
Alignment DONE
Refit rear lights and bumper. DONE
Tow hook. Rear Done need to sort front
Oil filter change DONE
Compression test DONE
Decal kit NEED TO ORDER
Tighten steering wheel attach face plate DONE
Wire in fan for windscreen DONE
Mount go pro DONE
Remount carbon canister Bracket made, to fit tonight
Find the coolant leak [Sad]
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pistol pete
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PostPosted: Wed Oct 16, 2019 2:21 pm    Post subject: Reply with quote Reply with quote including images

found the air lock, it was just after the thermostat.. all sorted and temps seem to be staying where they should be!

An utterly boring and pointless video for anyone but me...
but i done one as a momento of its first drives out
at the alignment shop.
then last night.
It drive well. went into lift .. pulled as it should i think (never been in one) and as said before its on the road and its wet so no hard pulls etc.. and stopping to check everything was okay every mile..

touch wood it seems okay..
hopefully the next video will be much more interesting on the track!! what it needs to be

https://youtu.be/3bk-7_Po5t8
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