GDII's SW20 MR2

  • Thread starter GDII
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Since last time I posted I have got a wheel alignment done. The car is quite different now.

5° caster which is pretty much max on the adjustable front rods. The wheels sit quite far forward in the wheel well now. Odd look but improves turn in but heavier steering. Power steering makes it easy though.
Max camber all round which is not much with stock suspension.
A bit of toe IN at the rear and toe OUT in the front.
Swaybars set to medium front and rear.

The car behaves how I want it to for the tight twisty stuff and is stable at high speed. The bushes have made the ride quieter and more comfortable. I think it also has helped the stability and steering response.

I have also got some more parts to add to the car that were missing when I bought it. Fog lights and the frunk trim.
I know the fog lights aren't anything special but I haven't had them for the 7.5 years I've owned the car so kind of special. :embarrassed:ops: :lol:

Rusty screw holding in the fog lights from the car I got them from. 1 out of 4 survived. The rest died with the drill.


Fog lights plugged in for testing. They were only placed there on the locating pin as I didn't have the screws I wanted to fix them to the car.




Ready for install


Before


After






I found some 304 stainless steel screws with the correct thread size and pitch. M5x1 I think.




Frunk liner installed.


Photos I took while out driving. I'm really enjoying the car now that I can use it without it leaving smoke screens everywhere and oil usage down to next to nothing. Still yet to see it go down.








 
SVX
Windy Wellington eh? ;)
Yip.

Haven't been doing much on the car until recently. Been driving it heaps though. The handling is great now. Cornering, the car is so much more stable and sits very flat. The car doesn't feel like it's being pushed even when cornering as silly speeds.
But I guess my perception might be a bit skewed due to driving an EP81 Starlet with 155/65R13 tires, no sway bars, worn shocks and tiny springs. The Starlet is definitely a fun car and can be thrown around easily but it's just very unstable and the tires lack grip.

I've been chasing an idle issue lately so thought it might be a vacuum leak. Spent the weekend putting 3 new intake manifold gaskets on but this hasn't fixed it.







 
Corolla's also been having idle issues, I think it's more due to the spark plugs needing to be replaced.

How long until I get to experience these silly speeds? :sly:
 
SVX
Corolla's also been having idle issues, I think it's more due to the spark plugs needing to be replaced.

How long until I get to experience these silly speeds? :sly:
Could be a gummed up idle valve. What engine doe that run? 1ZZ-FE?
Well that depends on what your definition of silly speeds are? PM me. Been busy with life and this car. Other than this small idle issue it drives perfectly fine.
 
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1ZZ yeah. That could be it actually - I'll have to do it. May as well check the spark plugs anyway, not like it's a Subaru. :P
 
They are only $5-6 each. NGK copper or Denso. Never use Bosch in a JDM car, the heat ranges are insufficient for most Japanese engines.

Getting to the idle valve would mean taking off the throttle body. Not too difficult.
Here's a diagram. http://jp-carparts.com/toyota/partlist.php?maker=toyota&type=151150&cartype=17&fig=2211

Ah that cheap? Awesome, many thanks. Was expecting $12 without actually searching it up. Should be able to afford it on my voucher I got for my birthday then with is a relief.

Ah many thanks for that, will probably do that at some point this week!
 
I went down the road with @SVX to grab some photos of the car with my new camera. All these shots are straight off the camera with no editing.


You can see here the affect on the front wheel position with the increase caster angle. It's no longer centred.
















 
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I, too, brought out the DSLR for some snaps:

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They all look great. It's nice to see a different perspective on photographing this car from someone else's creative mind. Pretty much 99% of the photos in here of the car are taken by me bar the few rally and autocross ones because I was driving.

Love the dark tones and the close up shots.
 
Excellent photos from the both of you! If all 25 year old cars were in the same condition as your MR2, nobody would ever need to buy new cars! So tidy! :drool:
 
Excellent photos from the both of you! If all 25 year old cars were in the same condition as your MR2, nobody would ever need to buy new cars! So tidy! :drool:

Thanks Hayden.

How many cars make it 5 years without getting bumps and scrapes on them? People use cars as appliances to get places with stuff. Not keep them in good condition like this one. I guess I'm just lucky this particular car is pretty straight. It has defiantly not been very reliable though. Many break downs and obviously another engine has gone into it. It at 237000km + now. It's probably had 75% of it's mechanical parts replaced now.
 
Stumbling back to the Members Rides section after a long absence. Good to see this thread still alive and kicking :) Still looking clean mate.
 
Stumbling back to the Members Rides section after a long absence. Good to see this thread still alive and kicking :) Still looking clean mate.

Thanks, it's going better than ever. The replacement engine is strong and the suspension refresh and minor mods have made the car even more fun to drive. I am very much enjoying the car so much more than I have before.
 
Been a while since I updated the project.

I've been chasing an idle issue for a while now and went around in circles chasing it spending a bit of money trying to fix the problem.
I looked at the idle valve, this was fine but I swapped it out for another one I had. This also changed the TPS as I swapped over a whole throttle body. This did nothing so I went back to the original one.
Then because it was idle hunting a bit when the problem first started I thought it might be a vacuum leak. So I went searching for a leak. I did fine some in the intake manifold so I replaced all the gaskets but this also did nothing much. It did drop the idle down a small amount as it should have.
Then I checked the ECU temperature sensor. When I unplugged it nothing happened and the resistance seemed to be out a bit but hard to test without removing it from the car. When I was playing around with Olafs turbo MR2 unplugging this sensor changed the idle. So I thought it might be this sensor so I bought a brand new one from Toyota, plugged it in and still nothing. This gets you a bit down when you've looked at most things that control the idle. But me being me I keep on looking.

So I pulled the ECU out and opened the lid to check for any damage to the components and board. Absolutely perfect condition so I move on.
The next thing I looked at was the continuity of the wires that control the IACV. I remove the ECU plugs in the boot and test the RSC pin, multimeter beeps, thats good. Next I check the RSO pin, multimeter beeps so that's good too.
Checking the B+ pin in the centre that provides power to valve produced no results, no beep. OK this must be the problem. This wires is connected to the B+ pin on the ECU and also powers other items like vacuum VSV for the ACIS butterflies and the B+ jumper in the diagnostics plug.

So after finding this I ran a test wire from the B+ pin in the diagnostics plug to the centre pin on the IACV plug. This worked and the idle changed as it should with engine temperature increase.
To fix this problem permanently would involve removing the whole engine loom to go right back to the splice point where this wire connects to the ECU B+ wire. So what I did instead was to untape the loom closer to the ECU and tap into the ACIS wire which connects to the same circuit. Cut the IACV power wire and join. All sorted, half a roll of electrical tape later and it's back to normal.

Retaping the loom


Finished taping.

The grey plug was the one causing me issues. The power wire seemed to be oily which is very odd.


The other issue I was having was a gearbox axle seal oil leak. This happened wit the engine swap but I never got around to fixing it.
So I thought I would buy a new seal and install it.

Off comes the right rear wheel, unbolt the hub from the suspension and unbolt the axle from the hub. All easy to do seeing as they were only removed recently. I greased up the splines on the outer shaft in the hub to stop it rusting in place.
Grab a hammer and a short length of timber and knock out the axle from the gearbox.
Removed damaged seal then clean up the gearbox for the new seal.





Then I went ahead and installed the new seal with this little SST (Special Service Tool) that I got my brother make for me as I didn't have any sockets big enough.



Tap it in gently with a hammer. Hold on, this doesn't look right, the seal is too far into the gearbox.



Silly me only really though about it after I had reassembled the car, filled the gearbox with oil and put it back on the ground. This left the car unusable until I could buy a new seal and install it properly flush with the outer face of the gearbox.

New (No.2) seal installed properly. Car put back together and oil put back in. I drained the oil into a clean container and reused it, the gerabox had never been used so it's still perfect.



Bonus axle photo....



I hope there are no leaks as when the seal was installed incorrectly there was an oil drip on the axle but that's probably due to the seal not being on the axle properly.
 
First drive of the MR2 for the year and after fixing the last set of nagging issues.

It's odd to have the idle rpm down below 1250, even more odd to see it being controlled and drop below 950 when it's at running temperature. Much easier to drive around town at slow speeds.
Before when you start the car from cold it would idle below 900 then with any small blip of the throttle the rpm would drop down close to stalling making it hard to reverse. Now it's up higher when cold and throttle blips don't let the rpm drop below 1000. I guess that's a result of no electronic idle control.

Also no more leaks from the gearbox, just need to clean up the outside of the casing from the oil that was leaking into the dust making it migrate everywhere.
 
I decided to take advantage of the weather tonight and get some unusual shots. I'm still getting used to the fact I have fog lights and seeing as it's only legal to use them in fog and very bad weather, I use them when I can.





















 
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I decided to take advantage of the weather tonight and get some unusual shots. I'm still getting used to the fact I have fog lights and seeing as it's only legal to use them in fog and very bad weather, I use them when I can.





I love those shots - especially these two :)👍
 
After getting married in 2015 we saved up for our honeymoon and left for Japan one year later.
Such an awesome interesting country. We spent 3 weeks over there traveling the country from north to south then back again.
While I was there I went to a few car related places. This post will cover car stuff only. I'll put in some other shots of places we went to in the next post.

First off we went to Toyota Megaweb on Odiba Island in Tokyo Bay. This is a giant show room of all their latest cars that you can sit in and even take some for a test drive around a short road course.
They also had a few of their race cars straight from the track, dirt, damage and all the rest.

Gazoo Racing Lexus LFA #83 Nurburgring 24h SP8 class winner 2012.




Gazoo Racing Toyota 86 #165 Nurburgring 24h SP3 class 6th place 2012.


Everything you need to turn a GT86 into a TRD version.




Toyotas Mirai Hydrogen powered car.


GT86 Police car


Initial D AE86 Trueno replica in the Venus Fort mall historic Toyota section.


1970 KPGC10 Skyline


1973 TE27 Sprinter


1967 MF12 2000GT Export Version for the US market.






1965 UP15 Toyota Sports 800


1971 Mazda L10B Sports Cosmo


1966 Nissan Fairlady 1600/Sports EDIT: Derp! 1966 Honda S600. Coz Honda badge....


There were a whole lot of model cars too.








AW11 features quite a bit in Toyota model collections throughout the country. Sadly the SW20 isn't to be seen much. The ZZW30 is more common in their collections too.


First car related purchase. Well a gift from the wife.
TRD keyring with carbon fibre embedded in it.


Then we headed up to Sapporo for the snow festival.
Random grey and green S2000


Then back to Tokyo to meet up with a school friend who lives there now. Having someone who speaks Japanese came in use for a few things I wanted to do, mainly buy stuff.
Some of you may know I am a closet Subaru enthusiast so I had to go to the STi showroom in Mitaka to check out what they had there.

In the showroom they had a few of their road going cars, some models you'll see here in NZ and others you won't unless specifically imported privately. But what I really wanted to see was the rally cars that were there.


Colin McRaes 1998 Sanremo Rally WRC #3
















Peter Solbergs 2007 Monte Carlo Rally WRC #7






And his 2008 car.






And a very special car to any Subaru lover. The limited 22B. This is one of the 400 built.


A couple of Subarus Nurburgring race cars.
2012 SP3T class winner #133. Based on the S206.




#120


A few other things they had on display.




A flexible strut bar, an interesting concept.








Looking out over the Subaru filled car park. You could test drive cars here too but I didn't get my drivers license while I was there due to the amount of train travel we did. Missed out on driving a new BRZ or 2015 WRX STi.


The history of STi started in 1988. Same age as me!








While I was there I bought a few things.

I got a cap and shirt.










And for my brother as a gift I got a key ring. He owns a 1998 WRX LTD so it works out.




When I went to pay for these items they brought out a box, luckily our friend was with us and could talk to the people at Subaru and she told me it was complimentary.


Inside the box was a document wallet, a card case, a keycase and a name stamp case. In Japan you carry a name stamp, it's sort of like your signature for singing/stamping documents.

The Japanese people are so nice. Thank you Subaru.

The next place I went for car stuff was one of the many Super Autobacs stores. These are effectively massive Repco/Supercheap Auto stores but you can buy so much more. Turbos, exhausts, wheels, tyres, in car entertainment. Everything you could want. They also run a chain of mechanics garages so you can get your car serviced or modified. Saw my first JDM in Japan R34 GTR being driven out of the shop. I've seen a few in NZ but it was nice to see one in Japan.

So I bought a few things from the TRD section.
TRD tire valve caps.


TRD radiator cap. Sadly when I got it home I realised it was the wrong type and doesn't fit an MR2. Owell, desk ornament.


And just because I want to own some genuine Japanese learner plates I grabbed these magnetic novice driver plates.


The next place we went was Toyota HQ in Toyota City near Nagoya. This was to go on a plant tour to the Motomachi plant.
This is where they make the Estima van, Mark X and versions of the Crown. This is also where they made 390,000 Supras until 1997.
Unfortunately the MR2 was built in the Miyagi Ohira Plant just north of Sendai of which they produced 300,108 from 1984 to 1999. I didn't manage to get to the birth place of my car. Owell.
The plant tour started in the welding shop where the car bodies were spot, arc and laser welded together. The majority of the welding is done by robots, 97% I think. It's quite odd seeing 6 different car models being built on the same assembly line at the same time. For example there would be an Estima then a Crown then another Crown then a Mark X in a row. The robots just figure out what body is coming next and change the way they weld or in the case of the Estima some of the robots would just vacuum the floor of the body to remove the weld spatter.
Next it was off to the assembly floor. The first thing we saw was a whole lot of pre-assembled parts ready to go into the production line. Then you would see car bodies moving along the line in the same order they left the welding shop but this time they were painted. As they move along the line each person has a little cart that gets filled with the required parts to be installed in their station. It would change depending on the car model being built or the optional extras a customer has ordered. Further along there was a sea of engines and gearboxes being prepd to go onto the production line and drop into the cars. Well not into, the car body would get lifted up and then the engine and drivetrain would go underneath then they would come together and get bolted on.
All this takes 20 hours to assemble a car from flat sheet metal to a driving car. Obviously there are a lot of pre-assembled parts that are put together by other plants of Toyota or other companies who make parts for Toyota.
They were making about 300 cars per shift with 2 shifts per day. They don't run 24 hours though.
At the end they gave us some pens which say on the back in Japanese 'Good Thinking, Good Products' which is the companies motto. The carts that carry the parts along side each station are an invention of the Toyota employees themselves who work on the production line. They are encouraged to come up with better ways to do things.

There was a museum there but most of it was just a 'buy our new cars' and 'look at our special GR (Gazoo Racing Edition) cars. There was a Yellow Lexus LFA there though.
What I really wanted was to go to the shop. So upstairs I went and bought more stuff.

Another key ring.




A TRD wallet






TRD Key case


TRD cap




TRD shirt


And the last car related thing I saw while heading toward Tokyo Tower was this Tommy Kaira ZZS EV. An electric car based off the ZZS.


That's pretty much all I went to see. While walking the street you mostly see Kei cars, Toyota Crown Comfort Taxis and of all things, scooters with large exhausts. I did see a few cool 80s and 90s cars but they are very hard to find in the larger cities. There is a large presence of LHD Porsche in Tokyo and quite a few European supercars and luxury sedans.

All in all we had a great time. This car stuff took up maybe 5% of what we did while over there. Going to see the country and the buildings was great. The culture and the people are all wonderful. There's always someone there to help us useless tourists. Getting around the country is actually really easy. Their transport systems are great.
 
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This covers the rest of the trip in brief. I had to pick from some of the 2250 photos I took so there is still a heap of photos to look at.

After the 2 flights from Wellington to Sydney then to Tokyo in planes that resembled sardine cans we were greeted with a great view from our hotel on the 34th floor.

Tokyo tower and Mount Fuji covered in snow.



And the view at night


View in the morning


The next day we got on a JAL (Japan Airlines) Boeing 777 and I expected to have trouble in the seats but I was wrong. They provide even more leg room than any NZ domestic flight. Oh BTW this is my first time leaving NZ so it was quite new to me. 1.5 hours later we were in Sapporo for the Snow Festival.

They build massive snow sculptures in Odri Park which is in the centre of the city.


A view looking down on the park from the top of Sapporo Tower.


Ice sculptures of various animals and things. Some had fish frozen into them.


Japan has Mascots for everything and most of them a completely crazy. This one is called Melon Kuma which literally translates to Melon Bear. He is the mascot for part of Hokkaido. Hokkaido is famous for Bears, Melons, Salmon and Crabs. Soooo they mutated a bear and a melon to become Melon Kuma. He eats everyone, including us.


Then we took a short train trip west to Otaru for the Lantern Festival.










Then it started to snow quite heavily so we headed back up to the train station. By the time we got back were were pretty much white and the tracks were covered in snow. But this is normal in northern Japan so everything keeps going.




Back to Tokyo for a week to go an explore the city.

Tokyo Sky Tree. Tallest tower in the world, second tallest building in the world. The top observation deck is 450.2m above the ground. As I am not very good with heights I stayed close to to middle most of the time.




Starwars exhibition in the tower. Storm Troopers anyone?


Shibuya crossing on a quite day. No drifting RX7 or EVO 8 to be seen.


We did a bit of Shrine visiting. Well, a lot actually, we spent most of our time doing this as this is what the wife wanted. See it's not all car stuff.














Some of you might recognise these next few photos.








Yes it's Gion from Gran Turismo 5 photo mode.

Sake barrels




Maglev train or Linimo (linear motor) line. It has no human driver and feel quite different to a conventional train. The vertical 'bumps' are almost non-existent but the sideways movement was at times quite jerky in the corners. It's not that fast but still a good experience. People use it everyday as part of their normal commute to work. It was built for the World Expo 2005.


The Shinkansen trains. These particular ones were double deck. We used the Shinkansen train a lot to get around Japan. Going 300kph is quite an exciting thing but in these trains it's very comfortable and you don't feel like you are going that fast due to the smooth acceleration and large radius corners. Most corners have a 4km min radius. Some in the Tokyo area are 2.5km though. Tons of tunnels so looking out the window is mostly just black.


We mostly took the N700 type trains.


Lantern festival in Nagasaki






A Bomb Dome in Hiroshima. While we were there we meet a man who was still in his mothers womb while she was in the city when the bomb went off. It was interesting talking to him about his side of the story.


Miyajima just south of Hiroshima. It's an island with a lot of wild deer roaming free with humans.
Also this massive 'floating' Tori gate.








In the evening we went out in a boat and went through the gate at high tide.




Another place full of lights.






Cheery blossoms







UFO thingy you can go up 45m in the air to look over the area.












Osaka Aquarium


Bamboo groves in Kyoto. Another Gran turismo photo mode location but this time from GT4.




Mount Fuji on the way back to Tokyo on the train.


That was only a small amount of what we did.

It was a great experience and well worth going. We both had a great time and really didn't want to leave. So we bought back every type of crazy flavored Kit Kat we could find along with other foods. We now have a stash of Japanese candy and snacks to slowly go eat our way through. A lot of the Kit Kats we brought back as gifts.

Japan, we miss you.
 
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Now back to the actual car.

After upgrading my swaybars I knew I needed to upgrade the links to something stronger as they are known to fail in one way or another even with the stock bars. Mine are already bent being the thin GEN 1 links and the joints are a bit worn out.
There are a few options around to get knew parts but some were rather costly or not quite right. So what do you do when you can't get something? You design your own and get them made. Big thanks to my brother for sourcing all the parts and making the rods to my design.

Custom 304 stainless steel swaybar links. Sorted. :twisted:












Custom engraving from the manufacturer.




Cap screws and Nylock nuts to make everything easy to install.


This shows the tapper and the thread being cut into free cutting steel as a test. The actual items are made from stainless and you need to use lubricant to cut it so you wouldn't be able to see anything as it splashes everywhere.
 
Just gone through all the pics above. Looks like a great trip! One correction though - the yellow 'Nissan Fairlady' is actually a Honda S600.
 
Just gone through all the pics above. Looks like a great trip! One correction though - the yellow 'Nissan Fairlady' is actually a Honda S600.

Ah yes, thank you. Because the freakin' massive Honda badge hanging off the front grille...
 
Nice pics from your trip, I'm jealous, I'd love to go to Japan! Those links looks really good too. I love bits that you put on your car and know they look awesome and you put a lot of effort in to but know that you are the only one who will see them lol. Well you and the forum anyway :)
 
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