With no group buys going on I took the opportunity to go to a breakers and I found a 36,000 mile 2GR-FE engine from a 2008 AvalonBought on 9th Dec 2010
Nothing goes to plan and I was expecting problems, but I didn't expect anything as heart breaking as this.
...The engine arrived at Woodsport and appeared to be very badly damaged and in an unsaleable condition.
- Both front bank camshaft sensors broken- One of the bellhousing bolt holes was snapped- The front bank cam cover had a crack on the top of the casing- The engine harness was badly chopped in several places- Oil pressure switch brokenThere were missing parts.
..- Upper dipstick tube and dipstick- Both Air fuel ratio sensors- MAF sensor and plug- Both Chassis to ECU plugsResponse from the Yard after my email saying that it was in an unsaleable condition.
.."You looked at this engine & inspected it before you paid for it. All I did was put it on a pallet & you took care of shipping. All of the parts shown below are not warranted . If you look at the back of your invoice you will see whats warranted".Quick run down of the problems with pics from Paul.
..Both front bank camshaft sensors broken.
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One of the bellhousing bolt holes snapped clean off the engine.
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The front bank cam cover had a crack on top of the casing.
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Engine harness badly chopped in several places.
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Missing parts included upper dipstick tube and dipstick.
Oil pressure switch broken...
The good news was that Paul could salvage it.
So a new shopping list was created:- 2 x AFR sensors- 1 x MAF sensor + pigtail- Both front bank Cam sensors + pigtails- Sienna pedal + pigtail- Upper dipstick tube- Upper dipstick tube o-ring- Dipstick- Axle Carrier bearing bracket- ECU, carrier bracket and connector housings- Both chassis to ECU plugs- Fidanza flywheel- ACT clutch- 2GR mounting kit- Headers- Exhaust silencer- LSD equipped Mk2 turbo gearbox and driveshafts, plus some modified rear hubs to take the thicker splineI bought a rolling MR-S shell from GTSChris.
I went this route because it cost less and with the shell being imported, it was very clean underneath.
Work started with Paul Woods in Jan 2012
Alterations carried out to the engine bay, certain areas recessed and the drivers chassis engine mount fabricated.
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The front subframe modified too, necessary for Marcs headers to clear.
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Gearbox hanger mount made
The Mk2 mount dummy fitted on the drivers side.
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The engine access hole cut and framework made for it that the removable hatch bolts to.
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The large core aluminium rad fitted, essential for a 2gr or 1mz in a roadster, the stock radiator is pathetically thin.
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Engine looks a lot nicer now compared to the previous pics!!
The engine bay prepped and primed.
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Then given a quick basecoat of gunmetal grey.
The engine trial fitted.
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This highlights any areas that need to be addressed and lets Paul make the torque mounts and modify the rear subframe.
All of the remaining fab work can now be done.
They really are a snug fit in a Mk3 bay.
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Start made on the gearbox side of the rear torque mount.
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Front torque mount fabricated, pre paint.
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The rear one with temporary bolts.
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A view from the rear, still a bit untidy.
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Fabrication stage complete, engine removed and bay given final alterations before getting a clearcoat on the basecoat.
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I've lost the first fire up videos.
It ran, but we had problems.There was a code P2103 coming from the ECU, which means the drive by wire throttle body had a fault.
It couldn't be ignored because it goes into limp mode and restricts throttle to 2000rpm.
So another throttle body was required!
I bought a 2nd hand throttle body from ebay US.
It arrived at Woodsport and comparing the two throttle bodies revealed that my old one had a ding in the body like it had been dropped. You could also move the butterfly by hand, which is not something you can normally do.So the ebay one was fitted, key turned.
.....nothing. 
Two codes from the ebay TB are:
P2103 Throttle actuator current
(high current) P2111 throttle actuator control system
- stuck openWe decided to get one of Paul's friends' 2gr into the workshop so we could cross over a known good TB and ensure the wiring is all OK.
It worked fine. So both previous TB's were at fault. Paul's wiring was good.I sourced another new TB, this time tested as working before it was sent to me.
Getting excited about picking her up, I gave her some new boots.
Rota Grid wheels in Bronze with Toyo T1-R tyres.
Front wheels:
15 x 6.5J +40Front tyres:
195/55/15Rear wheels: 16 x 7J
+40Rear tyres:
225/45/16
I finally picked the car up from Paul on 2nd May 2012.
On the way to Warrington to pick up my hardtop from Dick Sloan (MR2 Roadster breaker and all round helpful chap), I got a blow out on a brand new tyre! That's the M62 for you! Apparently loads of shards of metal on that stretch from the lorries. I managed to get recovered to Dick's. Dick had plenty more than a hardtop.
Because my MR-S was a shell, it had no interior, literally seats dash and steering wheel only. I spent all day at Dick's and he helped me install the entire interior and I bought a nice lip kit (TRD stage 1) that was on his latest breaker. He gave me a wheel and tyre to get home as well. Can't thank him enough!Stopped at a petrol station when I was on my way again and got a flat battery.
Had to get another call out to get a jump start. RAC man put the voltmeter on it. It was fubar'd. So new battery required!Finally got home in the wee hours of the morning.
First jobs I carried out the following week were new battery and new tyres for the front.
I dropped down a profile to 195/50/15.
