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JLee's 1991 Toyota MR2 Turbo build thread

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Status:

SARD 800cc injectors are here
ECU has arrived at ATS, but they haven't had a chance to look at it yet
Apexi S-AFC II will be on the way shortly to clean up fuel trim once the new ECU is in with the 800s
I need a new wideband (my Innovate decided to crap out on me)
Interior refresh will be coming as funds allow
 
Just got off the phone with ATS (again). They had another customer with the same problem I had and it was fixed by replacing the aftermarket spark plug wires with OEM.

One of the videos I sent ATS showed a Code 51, which wasn't in the Toyota manual until 1993 (I'm running 91-92 ECU). Code 51 has to do with the knock sensor circuit, which the ROM tune daughter board uses to communicate with the ECU somehow. Aaron explained a lot of the details but I don't remember or understand them all, but basically the aftermarket parts are fast enough to work in/around the OEM ECU through this circuit. Turns out aftermarket plug wires can cause interference that OEM wires do not -- causing wonkiness in the electrical system, and hence a stutter in the engine when the ECU goes omgwtfbbq.

This actually makes sense - when I installed brand new plugs, I ran for 60-80mi without a hitch. New plugs spark easily...but when they weren't perfectly new anymore, the coil had to send a little more power to fire the spark...and the plug wires weren't capable of running that without emitting any interference.

That's the theory, anyway. OEM Toyota wires and my ROM tune will be coming back to me shortly (as well as 1200cc top feed injectors for summer/fall, when I will get a top feed fuel rail, GSC 268 cams, ATS Racing adjustable cam gears, and a Megasquirt II plug and play EMS). :awe:
 
MSPNP. I researched the crap outa this last summer. I lost all my links though, when my puter harddrive fried. Do you have any experience with it?

I was planing to install it in my silver MR2 this spring but got side tracked with the MK1.5 🙂
 
FuzzyDunlop said:
MSPNP. I researched the crap outa this last summer. I lost all my links though, when my puter harddrive fried. Do you have any experience with it?

I was planing to install it in my silver MR2 this spring but got side tracked with the MK1.5 🙂
Click to expand...

JCH13's turbo Miata is running a Megasquirt system.

www.diyautotune.com is where I'll be getting mine (when it's released).
 
jlee said:
JCH13's turbo Miata is running a Megasquirt system.

www.diyautotune.com is where I'll be getting mine (when it's released).
Click to expand...


It looks like fun. Complicated but fun.
I bought mine from Mulry at MR2OC. SO I know its a running system. He was using it in a track car and fried his engine because he was revving up to 11.000rpm which prevented the rings from getting oil properly - or somethign like that.
I wont be revving that high.
 
I love the MS, the possibilities are endless...

Launch control
Flat-foot shift control
Anti-lag control
Meth/water/NOS staging and injection
Shift light control
Custom hard and soft rev-limits (someone else driving car? burn a quick low-rpm rev limit!)
Custom fan temp control
Multiple custom fuel and spark maps
Boost-cut limiter

I can go on...
 
JCH13 said:
I love the MS, the possibilities are endless...

Launch control
Flat-foot shift control
Anti-lag control
Meth/water/NOS staging and injection
Shift light control
Custom hard and soft rev-limits (someone else driving car? burn a quick low-rpm rev limit!)
Custom fan temp control
Multiple custom fuel and spark maps
Boost-cut limiter

I can go on...
Click to expand...

dude I just mega squirted all over my screen
 
JCH13 said:
I love the MS, the possibilities are endless...

Launch control
Flat-foot shift control
Anti-lag control
Meth/water/NOS staging and injection
Shift light control
Custom hard and soft rev-limits (someone else driving car? burn a quick low-rpm rev limit!)
Custom fan temp control
Multiple custom fuel and spark maps
Boost-cut limiter

I can go on...
Click to expand...

how was the learning curve (although I may be talking to the wrong guy about it because you are a genius)? Was it tricky to get used to? ever accidently cause damage somehow?
 
FuzzyDunlop said:
how was the learning curve (although I may be talking to the wrong guy about it because you are a genius)? Was it tricky to get used to? ever accidently cause damage somehow?
Click to expand...

I read, and then re-read, and then re-read all of the documentation before I got started, specifically what options in MegaTune (now Tuner Studio) did what. The menus sometimes are confusing, but if you read the documentation it all makes sense. There are pretty good help files for every main option window, and even some of the obscure ones. It didn't take TOO long to learn what everything does, but there are some subtle things.

Tuning fuel and spark maps are super easy, they're even color-coded.

There is an option to go through every active option in a single instance to double-check and make sure you didn't miss anything.

Having said that, this was back before the days of PNP mind you, so I had to fill out every little detail from scratch. First I got timing 180deg out, so instead of an engine I had a flame thrower (awesome, but doesn't run too well :sneaky🙂. I've backfired engines and blown up weakly-made intake manifold (a cast stock one would be fine I think). I've totally messed up spark and gotten a whole exhaust manifold, turbo hot-side, and DP bright orange. Never really screwed up fuel (i.e. way too lean) that is pretty hard to do if you're even a little bit cautious.

I guess that's a long-winded way of saying "you can mess up really bad, but most engines are pretty tolerant" especially if you're just getting things fired up. Again, PNP takes 99% of the hassle out of it, and the new tuner studio will auto-tune fuel maps very well.
 
JCH13 said:
I read, and then re-read, and then re-read all of the documentation before I got started, specifically what options in MegaTune (now Tuner Studio) did what. The menus sometimes are confusing, but if you read the documentation it all makes sense. There are pretty good help files for every main option window, and even some of the obscure ones. It didn't take TOO long to learn what everything does, but there are some subtle things.

Tuning fuel and spark maps are super easy, they're even color-coded.

There is an option to go through every active option in a single instance to double-check and make sure you didn't miss anything.

Having said that, this was back before the days of PNP mind you, so I had to fill out every little detail from scratch. First I got timing 180deg out, so instead of an engine I had a flame thrower (awesome, but doesn't run too well :sneaky🙂. I've backfired engines and blown up weakly-made intake manifold (a cast stock one would be fine I think). I've totally messed up spark and gotten a whole exhaust manifold, turbo hot-side, and DP bright orange. Never really screwed up fuel (i.e. way too lean) that is pretty hard to do if you're even a little bit cautious.

I guess that's a long-winded way of saying "you can mess up really bad, but most engines are pretty tolerant" especially if you're just getting things fired up. Again, PNP takes 99% of the hassle out of it, and the new tuner studio will auto-tune fuel maps very well.
Click to expand...

whaaaaat?! It didnt give you a "DANGER TO MANIFOLD!" warning for this?? lol
 
FuzzyDunlop said:
whaaaaat?! It didnt give you a "DANGER TO MANIFOLD!" warning for this?? lol
Click to expand...

:awe: rofl

It was on a race car... the plenum blew off the runners, the restricter blew off the plenum, the throttle body blew off the restricter, the filter blew off the throttle body, and the plenum went from a shape you might describe as "box-like" to one you'd describe as "football-like". The MAP and IAT sensors also blew out and were dangling by their respective wires.

Good times with starter fluid... 😀
 
Goodies arrived from ATS Racing - new OEM plug wires, my ROM tune, and 1200cc top feed injectors for future use. :sneaky:

SARD 800cc injectors (top) vs 540cc injectors (stock is 440cc):
injectors.jpg


Throttle body removed to access fuel rail:
injectors2.jpg


Partially reassembled after injector swap:
injectors3.jpg


To hopefully solve the stuttering problem, new OEM Toyota plug wires. They don't come cheap ($88), but if it fixes my problem it's well worth it:
newwires.jpg


Back together:
injectors.jpg


Safety measures, in case something goes horribly wrong:
justincase.jpg


First start!

It ran a bit rich at first, but after a few minutes settled in to ~15:1 AFR, which is great. Ideally I'd idle/cruise at 17:1 with E85, but that'll happen once I get a proper standalone ECU.

20-22psi is now safely within reach! I am limited to 15psi on 91 octane gas (280whp). I made 328whp at 21psi, so this'll be about a 50whp jump from before.
 
Wash/wax this morning. I should wax it again this week, and repeat every two months until I get a garage. 🙁

mr2-05-12.jpg


mr2-05-12-1.jpg


mr2-05-12-2.jpg


mr2-05-12-3.jpg
 
You cant use "PSHHHH" with a recirc valve, let alone no externally venting BOV.

:colbert:


PS get a scrub brush and some tire shine :awe:
 
FuzzyDunlop said:
eagerly awaiting video of 20PSI pull.
Click to expand...

Haha, me too. I need to go over my intercooler piping again - I think I have a boost leak that wasn't present at 13psi.

I also ordered a one piece hot pipe from RacerX Fabrication - bigger diameter than stock, looks a lot better, and eliminates a coupling/two clamps.
 
jlee said:
Haha, me too. I need to go over my intercooler piping again - I think I have a boost leak that wasn't present at 13psi.

I also ordered a one piece hot pipe from RacerX Fabrication - bigger diameter than stock, looks a lot better, and eliminates a coupling/two clamps.
Click to expand...

Seems it wasn't a boost leak - I have oil in my boost control solenoid which was causing all sorts of hell. It may be time for a PCV catch can.

RacerX hot pipe next to stock assembly:
hotpipe.jpg


Old stuff removed:
hotpipeinstall.jpg
 
hotpipein.jpg


Back together!

I found a split in the vacuum line going from the compressor housing to the boost control solenoid, which may have contributed to the bucking issues I was having when using the boost controller. I also cleaned the solenoid with electronic-safe cleaner, so hopefully any motor oil is gone now.
 
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