MR2 TDI

Author
Discussion

cookie nom nom

6 posts

113 months

Tuesday 18th November 2014
quotequote all
that Laugh at the end of the vid. cant wait to see what its going to be like at once built!

lozzzzzz

Original Poster:

339 posts

156 months

Monday 1st December 2014
quotequote all
Another small update. The rough running is sorted, and I've been working on the tank.

Got it off the car:


Cut off the toyota float, and fixed the swing arm in place, then attached the TDI tank sender to get the right signal to the dials.


Then had to put it back in in a different orientation so it could still move up and down freely:


Then pulled the impella out of the fuel pump so its now effectively a pipe:


And re-assembled it:


I've got a new cam belt, water pump, oil filter, fuel filter and oil to change, then the MFA/cruise switches to wire in then the loom can finally start going into the car.



In a break from MR2 stuff….
The Scimitar ran out of tax yesterday. As a little treat, I took it up to Rhayada for a late night blast. It was a lot of fun, not another car for miles smilesmilesmile

Hope you like the photos. (fireworks was taken on bonfire night)








And for the grand finale (this shot took a long time and included an 11 min exposure):


anonymous-user

53 months

Monday 1st December 2014
quotequote all
Great pictures.

aka_kerrly

12,415 posts

209 months

Tuesday 2nd December 2014
quotequote all
This is brilliant!

I especially like the starting of the engine before it's even in the bay , you looked like a kid at christmas playing with a new toy.!!!

lozzzzzz

Original Poster:

339 posts

156 months

Saturday 13th December 2014
quotequote all
Hello again. I've made quite a bit of progress recently but haven't really had time to post about it. Well here is a bit of an update.

I've changed the cambelt, idlers and water pump (but was disappointed to find they were in really good condition so could have saved a load of money)


I've cut of the bits I don't need leaving just the tensioned and alternator:



Next was to sort out the horrendous throttle and EGR situation. The crank case gas recirculation means that oil makes it into the inlet and the EGR means that soot gets in there too, the combination means an epic building up of black crud (you can see it in the photo below). The already small inlet pipe had 8mm of caked on crap so that was cleaned out. The EGR was welded up (using bird poo, check out that weld) and the throttle and EGR valve was binned. In fact I went further than that and cut the elbow of the manifold completely. (The throttle is only used when the engine is switched off, it creates an inlet manifold vacuum, just like in a petrol car. Less gas in the cylinders means less compression and the engine spins gently to a stop, rather than the abrupt shaking you can get with older diesels. I can live with that for more power.)


Imagine the restriction this was giving:


This is after cutting:


I then cleaned and ported the manifold a little and used the rubber hose straight onto the manifold:


All done:




I've found a 760mm belt to drive just the alternator:


Yesterday I started messing about with the intercooler to see if I could get it to fit against the MR2s side duct. The plan being to use a micro switch under the throttle to switch on the fan and pull air through the intercooler on full throttle.



Its still not perfect really, I'll keep pondering this one.

I tested to see if the throttle pedal feel was ok if I just connected up the MR2 pedal to the TDI variable resistor.


It was great, good pressure needed to push it (it just supports the weight of your foot) and a decent amount of travel (a little less than previously but still plenty for accurate control). So I welded a more permanent version into the under bonnet space.


And the last thing I got done yesterday was to attach the clutch pedal switch on to the MR2 clutch pedal (as I plan to have cruise control).


Sorry for the crap images, I was using my phone again. I'll take a better camera next time.

More to come

lozzzzzz

Original Poster:

339 posts

156 months

Thursday 18th December 2014
quotequote all
I made a bit more progress last night.

Lots of grinding away at the old MR2 dials, trying to get the TDI dials to fit inside. On paper that sounds like very little progress, but.. I did spend a while looking at it and figuring out how it was all going to come together. I'm pretty sure I know how to finish the interior side of things now. The dials are officially in (although the dead space either side of the TDI dials still needs painting black). I'm going to have a number of switches on a panel in the spare space above the radio (its double height), including the MFA, cruise control and perhaps a switch for the little power booster thingy (resistor).

Very pleased with progress I was too.

Forgive the dust all over the clear plastic, I haven't cleaned anything after grinding yet:


More to come

lozzzzzz

Original Poster:

339 posts

156 months

Thursday 1st January 2015
quotequote all
Right then! A much needed update.

I've got the dials looking how I want them to now, and they're fully wired in, and fully working smile But as I was putting them in for the last time I cracked the Clear plastic (the toyota bit). I'm a little gutted but this can be easily replaced at some point when I have more money to spend. (you can't see it very well in the photo but the crack goes from the top down through the speedo)


The illumination adjuster now serves no purpose so I've blanked it off.


I've reached a point where I really need to get the engine in before any other work can progress. So I cleaned up the garage and lined the engines up to get an idea where the TDI will need to sit in the engine bay.




Then set about making the first engine mount.


I got these bars to the same length and flattened the ends on the lathe:


Drilled them out on the lathe:


These will mean I can use the same three bolt holes that VW intended:


Cut a plate to shape:


And welded on the engine mount:


This is ready for a trial fit on Sunday (I'm very excited), if all goes well I'll start looking at the gearbox mount and add some bracing to this mount.

It is with regret that I'm altering the budget of this project, I'm now having to reduce costs as much as possible. This mainly means it'll be on the rather nasty 14" wheels for a bit (the gearing will be 5% down, i.e. more revs for the same speed) and the engine tuning will be in the form of decat, decoke and fit the +35hp "chip" (resistor). it should still match the brothers fabia VRS though smile

More to come

furrywoolyhatuk

682 posts

153 months

Friday 2nd January 2015
quotequote all
Brilliant!

lozzzzzz

Original Poster:

339 posts

156 months

Sunday 4th January 2015
quotequote all
Thanks Furrywoolyhatuk


I got the engine in this morning. Very excited about that smile

Its only attached by one engine mount and mostly hanging on the crane, but it was a great success in terms of seeing how well it fits and checking where things might go:



There is loads of room behind, I was worried about this area:


Then I took it back out and finished off the engine mount I had tacked on:


I drilled out one of the gearbox bolts that snapped off in the TDI gearbox (what a horrible job!)


And began making the gearbox mount:


That's all for now

More to come

TehRin

146 posts

113 months

Sunday 4th January 2015
quotequote all
Toyota MR2 PD115 (plus a little bit of fettling and a remap? wink ) - I love the idea. You might even confuse a few people when they see an MR2 rolling coal, or even hearing it! biglaugh

lozzzzzz

Original Poster:

339 posts

156 months

Tuesday 6th January 2015
quotequote all
I can't wait smilesmile

NashGT

467 posts

182 months

Tuesday 13th January 2015
quotequote all
Top work, very impressive and unusual project

5harp3y

1,942 posts

198 months

Wednesday 21st January 2015
quotequote all
Bookmarked, great read

LasseV

1,754 posts

132 months

Wednesday 21st January 2015
quotequote all
TehRin said:
Toyota MR2 PD115 (plus a little bit of fettling and a remap? wink ) - I love the idea. You might even confuse a few people when they see an MR2 rolling coal, or even hearing it! biglaugh
Slowest MR2 like ever.

getmecoat

lozzzzzz

Original Poster:

339 posts

156 months

Sunday 25th January 2015
quotequote all
Considering the significance of getting the engine mounts done, this is pretty lame update as I forgot to photograph the engine finally sitting in the car with no crane assistance.

Anyway, the engine mounts are now all finished and painted and while I have the stone-chip gun going, i took the opportunity to spray a few little places low down in the engine bay that looked as though they would appreciate some rust prevention.






Still need to drop the tank one more time and remove the gauze, sort the clutch hose while access is easy then pop it in for the last time smilesmilesmile

More to come.

5harp3y

1,942 posts

198 months

Monday 26th January 2015
quotequote all
great work

hornetrider

63,161 posts

204 months

Wednesday 28th January 2015
quotequote all
What a brilliant thread!

The Turbonator

2,792 posts

150 months

Wednesday 28th January 2015
quotequote all
Great thread op. Where did you learn and gain the experience to do all this?


lozzzzzz

Original Poster:

339 posts

156 months

Friday 30th January 2015
quotequote all
Thanks all smilesmile

I just picked it up as I went along really. I bought a 4x4 to rag about in when I was 14 and messed about with that (tried to keep it going). Half of it is having the balls to take something apart that works perfectly well smilesmile

lozzzzzz

Original Poster:

339 posts

156 months

Sunday 1st February 2015
quotequote all
The engine is in, hopefully for the last time. All the mounts are firmly fitted.

I did find a problem though. I had made the gearbox mount with the clutch slave not attached and guess what, it didn't fit. But after some adjustment all is well.


This is the third mount that stops the engine rotation, I'm a little concerned that the rubber bush is a bit rigid and might transmit a too much diesel vibration into the car, time will tell!


The clutch hose is all plumbed in, I'm really please with how easy this was (perhaps that temping fate as I've not bled it yet smile )


And a couple of shots of the engine in its new home:



One of the things that was bugging me was how to mount the intercooler. Well that's sorted now smilesmile

These are the bits that need holding together (the black plate with the big hole mounts to the car body).


It turns out they fit together quite nicely. Two of the fan mounts line up perfectly with two notches on the intercooler, holding it in place, its like it was meant to happen smile

So I've attached a strap and a bolt to tighten it against.



And painted it.



That's all for now. There are some reducers on the way so I can connect up the boost piping, then I'll put it in place and start the more plumbing or wiring.

Was a good weekend, I felt like I've made some good progress smile

More to come