2zz-ge Mk1 build

Discussion and technical advice for 84-89 AW10 & AW11 MR2. 3A-LU, 4A-GE, 4A-GZE.

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PW@Woodsport
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2zz-ge Mk1 build

Post by PW@Woodsport »

This one is a another first in the UK, we have been building up to this one for quite a while planning it out, and promises to be a fantastic conversion, so here goes!

We started out by giving Mark his dream gearbox, a Corolla T-sport 6 speed unit, but then stripped it down and installed a Mk3 Mr2 LSD unit and also swapped in the 6th gear assembly from the Mk3 (better 6th gear ratio than the Corolla 6th).

The box was then converted for Mr2 use by making custom selector rods coming out the front end of the Corolla casing instead of the rear.

We broke the whole Corolla T-sport several weeks ago and ended up with this....

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Mark then sourced the aftermarket exhaust manifold because the Corolla one was just unworkable in the Mk1.

This is Marks engine bay with 4a-ge....

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And about an hour later it was on the floor...

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Nice empty engine bay...

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So LOTS to do, but i'm looking forward to this one, should retain the high revving nature of the stock engine without any weight penalty.
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Neil_turbo
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Re: 2zz-ge Mk1 build

Post by Neil_turbo »

We have a corolla t-sport and the engine is fantastic, will be fantastic in a mk1!

Have wanted to see this done for a while and can't wait to see this one finished!
PW@Woodsport
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Re: 2zz-ge Mk1 build

Post by PW@Woodsport »

Yeah it should be pretty good, we have also managed to find a way to retain the Corolla supported shaft set up (previously all 2zz Mk1's in the US use unequal Mk2 NA shafts) , but we dived into the Toyota parts bin and found a combo of shaft bits from Mk1,Mk2 and Mk3 to make a hybrid supported shaft that will work on this car.
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PW@Woodsport
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Re: 2zz-ge Mk1 build

Post by PW@Woodsport »

The 2zz is now in the bay, with just one engine mount to make on the drivers side. I think i am going to make a bespoke mount that joins the old chassis mount onto the new 2zz bracket, that way it keeps everything reversable if mark ever feels the need to put a 4age back in :)

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PW@Woodsport
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Re: 2zz-ge Mk1 build

Post by PW@Woodsport »

Today i sorted the drivers mount out, there were several ways to do it, we looked at making an adapter to go between an upside down Mk1 mount and the Corolla bracket but it was just going to be too long and have too much stress on it, so i wasn't happy with that idea. Instead we made extension plates that are welded onto the chassis mounts, this holds the Mk1 mount in the right place and after we filed out the holes a little the mount went on. The engine now sits perfectly level on all axis. I still have to seam seal and paint the mount but you get the idea. On the next 2zz build i'd probably cut the Mk1 mount off entirely and make the whole thing from scratch, we saved having to drop the engine out again doing it this way. The mount is also working the way it is supposed to (as it is on a 4age), which i like.

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Also the rad and heater pipe plumbing is done, nothing hard, just joining A to B...

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One of the major parts of this build is constructing all of the gearshift cable assembly.... basically nothing bolts up, do not believe all you read on the internet folks! So i am making the cable bracketry from scratch. This is done by selecting Neutral at the shift levers, and positioning the gearstick right in the centre of the gate and securing it there while the brackets are made. So far i have only managed to make the first parts that the cables clip into, i need to add a lot more support and brackets to this to stop them moving, at the moment they are not secured to anything other than the cables, but the cables themselves have a nice free run without any obstruction at all.

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Mark wants this conversion to be quiet, so induction kits and loud exhausts are out. I am making some pipework that runs from the throttle body to the Mk1 airbox, so it should all look very OEM as well...

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I have to make a section that fits where the yellow box is, for the Maf meter.

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By Friday everything should be done bar the exhaust and wiring.
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PW@Woodsport
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Re: 2zz-ge Mk1 build

Post by PW@Woodsport »

Today saw the gear cable bracket assembly finished.... i basically gave up on all of the current information out there on the web at the moment and made my own.

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Here it is fitted with the clutch line bracket welded on...

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The gearchange works perfectly, nice and slick with no tight spots anywhere, and the beauty of this custom cable assembly means i haven't had to touch a single thing at the stick end, that is all stock. You will notice we have also polybushed the front torque mount, we did the rear one as well.

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I also made the Maf adapter...

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Here it is fitted with all intake plumbing finished...

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Also above the fuel pressure regulator is fitted, this allows the return style Mr2 system to have a working return, plus we can control the pressure.

An overview of the bay now, just wiring and exhaust to go... you will notice i have had to turn the battery 90*, space is tight but it all fits.

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Neil_turbo
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Re: 2zz-ge Mk1 build

Post by Neil_turbo »

would love to be taken out in this if your reading Mark :thumleft: Please!!! :)
widster
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Re: 2zz-ge Mk1 build

Post by widster »

Yes, this sounds a great conversion. What power are we talking for this engine?
Jaspa
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Re: 2zz-ge Mk1 build

Post by Jaspa »

widster wrote:Yes, this sounds a great conversion. What power are we talking for this engine?


http://en.wikipedia.org/wiki/Toyota_ZZ_engine#2ZZ-GE
I asked God for a bike, but I know God doesn't work that way. So I stole a bike and asked for forgiveness.
PW@Woodsport
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Re: 2zz-ge Mk1 build

Post by PW@Woodsport »

Today saw the last of the plumbing completed, i fitted a Mk2 filler neck which has been T'd into the radiator pipe making this the highest point (vital).

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Here is the Mk1 expansion bottle back in its former home, now i had to remove the brake servo pipe and reroute the servo pipework so that left me with a rather nice pipe with brackets on it that lined up nicely with spare holes in the rear firewall, a perfect coolant overflow pipe.... how's that for recycling? Woodsport, helping save the environment lol.

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Just exhaust and wiring to go.
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MartG
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Re: 2zz-ge Mk1 build

Post by MartG »

That engine looks right at home in there :thumleft:
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Lauren
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Re: 2zz-ge Mk1 build

Post by Lauren »

Brilliant work, really like the idea of this one. :+:
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rexer200
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Re: 2zz-ge Mk1 build

Post by rexer200 »

Neil_turbo wrote:would love to be taken out in this if your reading Mark :thumleft: Please!!! :)


If ever your near London I'm sure this could be arranged.

The reason for asking Paul to do the 2ZZ transplant for me in the first place was that I wanted to maintain the character, ride and handling of the MK1 whilst giving it a bit more zing :-)
This is my road car after all so stuff like reliability, economy and quietness are also important. Seems like quite a long list I know but the great thing about this conversion is hopefully I'll get all of the above. Paul has done a great job and he's involved me in every step despite me feeding him some duff internet info.
Well done Paul, you've now also just added practicality to my list by keeping the battery in the engine bay, well chuffed with that :-)
Neil_turbo
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Re: 2zz-ge Mk1 build

Post by Neil_turbo »

Cheers :D

I'm actualy near manchester, but will let you know next time i'm down that way! :thumleft:
PW@Woodsport
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Re: 2zz-ge Mk1 build

Post by PW@Woodsport »

Well after a bit of spaghetti juggling today she fired into life! Still no exhaust fitted so a video will come after i've done that, but it runs.

I had a few issues with missing power feeds from the ISCV and MAF sensor not to mention an immobiliser issue which threw a few surprises but nothing we couldn't overcome. I have had to make a Mk1 oil pressure sensor adapter to screw into the oil filter housing instead of the 2zz idiot light sensor and i have also had to make a water housing that fits inline on one of the rad pipes so we had somewhere to run the coolant temp sensor (for dash gauge).

So just the exhaust to sort and debugging (if any!)
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Jim-SR
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Re: 2zz-ge Mk1 build

Post by Jim-SR »

how hard was the wiring Paul? is it fully OBD-II functional? and what did you do about the dashboard?
PW@Woodsport
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Re: 2zz-ge Mk1 build

Post by PW@Woodsport »

Hi Jim, i would describe the wiring as tricky, but i would also say i enjoy hard wiring problems so for the man on the street the wiring may well be described as hard.

I have fully wired this one so it is still OBD2 compliant, there is an OBD2 socket now in the boot for pulling codes and if a sensor is pulled off the engine it will light the CEL and log a code. I insist on getting the OBD2 socket working on all my swaps otherwise it makes diagnostics in the future a right pain in the a$$.

I had to retro fit the mk1 oil pressure sender into the block to give the clocks its correct reading, and also make a new coolant sensor housing which sits inline on one of the rad pipes for the Mk1 temp sensor, the EFI sensor is still there informing the ECU as it normally would.

That is about it, i haven't run it for very long so not sure if other codes are going to appear but so far it's clean.
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monkeymax
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Re: 2zz-ge Mk1 build

Post by monkeymax »

This is an amazing swap - been looking forward to it for a while!! If I do a swap on my N/A, this'd probably be the route I'd go for because:

rexer200 wrote:The reason for asking Paul to do the 2ZZ transplant for me in the first place was that I wanted to maintain the character, ride and handling of the MK1 whilst giving it a bit more zing :-)


Exactly my feelings... ;)

How easy is it to find the engines?

Also, 6 speed gearbox... Yummy!! =P~
MartG
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Re: 2zz-ge Mk1 build

Post by MartG »

monkeymax wrote:

How easy is it to find the engines?


Just look for written off Celica 190/T-Sport or Corolla T-Sport.

Paul, do you think there's room in there for the supercharged 2ZZ-GE from a Corolla Compressor :twisted:
PW@Woodsport
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Re: 2zz-ge Mk1 build

Post by PW@Woodsport »

Absolutely :thumleft:
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