how to swap a 2grfe V6 into a st204, Toyota reliability, with less moving parts than a turbo Options

[njccmd2002]

Will start an official thread, into this. wont go into detail. Will keep it mostly informative, because i know this will not be a favorite swap for most, and will be cost prohibitive for many.

Approximate cost of swap is around 7 to 8K, and will vary according of how far you want to go. mods and stuff

not going to get into detail about, a shopping list, or what not. there are multiple places you can get it, and it has been discussed before.

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the engine fits, and it barely makes it. will not fully disclose all that is being done, but will mos likely help anyone that wants to do this personally.

fitting the engine and mating the engine, can be found in the MR2OC forums, and i will not take credit for it.

Please lets not fill this thread with garbage. Its a 2grfe, because i wanted it, and if you dont like it, oh well, you are not paying for it, lol....

first things first, the engine needs to come from the bottom, it wont come from the top... it wont...

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there are some body modifications, and will get into details later in the swap... I have my reasons.

the swap is doable. and like I said, im willing to help personally to any member, that will do it.

Will be a slow guide, because i decided to do it all myself, with no help. I feel like this is more personal....

Will include more stuff in the days to come...

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just consider the 2grfe, its worth it. all aluminum...

This post has been edited by njccmd2002: Sep 22, 2017 - 7:15 PM

[njccmd2002]

It wont clear the regular hood, but it will clear a gt4 hood, with some modifications to be confirmed...

there is some tapping and drilling to be done to tranny, and engine.... (all is covered in MR2OC), and all credit goes to guoky...

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and how the pros do it to mount their engines to the tranny. using headless bolts

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This post has been edited by njccmd2002: Sep 20, 2017 - 10:00 PM

[Smaay]

if I recall, the 2GR bolts right up to the E153 with no drilling or mods. use ST205 mounts and you have 3 right off the bat.

Im surprised you cant get the engine installed from the top, I can pull the 3S-GTE and AWD trans out the top with no problem. and the 3MZ went in with no problems either.

I cant wait to see your finished product, ill never go the 2GR route unless an engine falls in my lap for free. im really happy with the 3MZ.

[njccmd2002]

The engine is easier to maneuver from bottom. Its bulky and it hits the frame several places. You have to disconnect a/c lines and ps lines. I have to cut the frame. And there is barely space for the regular rad fan. Its just to bulky. I dared not try and get it jammed.

I understand your point. Yes its expensive. And its not for everyone. By all means its not the best swap. But this is the last thing o do to my car and wanted to do something memorable. Lol, i still dont know if ill be able to clear the rack with the headers.

[njccmd2002]

ok few more bits of information...

you just cant go straight to make the engine mount. you need to have a temporary mount to give you an idea of what needs to be cut and addressed.. in the engine bay. i suggest like i said earlier to remove the power steering an lines, and the a/c lines, unless you want to run the risk of damage...

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not yet sure if there is enough space for guoky headers in the rear, they fit for the front..

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Smaay, the upper bolt needs to be tapped.. its smooth. and you have to grind the engine in certain areas to mate the transmission..

front bracket area

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rear bracket area

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oh and forgot, fan relays are no go, move them

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This post has been edited by njccmd2002: Sep 20, 2017 - 10:16 PM

[njccmd2002]

oh and if youre going to be grinding, protecto engino

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This post has been edited by njccmd2002: Sep 20, 2017 - 10:19 PM

[richee3]

Berto, you cray cray! Good progress with the 2GR so far. Very brave for tacking this swap in a Celica with virtually no support.

[njccmd2002]

Thanks, was hesitant to make a swap thread, but i said WTH...

anyways... here is why you shove this engine from the bottoms...

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this is the engine mounted, and on the temp mount...

but that is not a problem..

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obligatory swap picture...

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and finished..

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i had to pull this engine 6 times up and down, up down to measure the cutting and notching the frame...

i had to notch for the head, and steering pump....

this is another angle from the crossmember.. you barely have clearance..

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and

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a stupid trick to line up the engine i learned...

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and once again, out, awaiting flywheel, and i will clean the transmission. its dirty...

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and while that is out, this may get refreshed..

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still lots to do, and so little time...

This post has been edited by njccmd2002: Sep 20, 2017 - 10:55 PM

[Box]

Damn, that's a tight fit.

I can't wait to see it all buttoned up.

This post has been edited by Box: Aug 13, 2014 - 10:20 PM

[bloodMoney]

Love this. Great work Berto!

[enderswift]

You are living our collective dream Berto. Awesome work

This post has been edited by enderswift: Aug 14, 2014 - 9:47 AM

[Bitter]

[kevin311]

Glad you decided to make a thread. F*** the haters. The price tag on this deters me but I'm down for someone taking a crack at something new for the 6gc. I commend you though for doing this on your own. Can't wait to see and hear the end result. Nice work!

[njccmd2002]

thanks, no updates for now, except got the aluminum flywheel, and suspension parts, totaling 800 this month. so i fugured will wait next month, for more parts, and work with what i have. No rush to do this yet.

[Smaay]

keep up the good work and the updates

[presure2]

this thread is already so full of win, most people who see it wont even grasp how goddamn cool this is.
i cannot wait to see this car in person in a couple weeks!
sure, cost is thru the roof.
sure, gotta have balls big enough to modify the chassis to suit.
sure, this is gonna be the fu^king coolest v6 swap on this site by about 8 billion miles!

DOOO ITTTTT berto!!!!!!

[richee3]

Updates?

[FORGMANN]

I know many of you are think man this would be sweet turbo'ed and in a ST205
Wonder if you can use 4WD gearbox ? Below is your answer posted in July
Anyone from Russia or eastern Europe have any more details on swap?
i could not find any anywhere .. Those crazy Russians tuners
Do not post here if you do start a new thread .

Avensis (same chassis family as st246 Caldina and 1ST gen TC)

https://www.youtube.com/watch?v=MkstuZACBQI

https://www.youtube.com/watch?v=lsQv-1zZq9w

Berto
Once you get running and then get power hungry again afterwards
i will have extra TRD S/C waiting as i now have 2 .. We all know 276 whp is never enough HP!!

[njccmd2002]

haha, yeah!. gonna have to chop some hood!!

ill put some work in it tomorrow and friday. this is really slow......

too many things in right now...

[richee3]

It doesn't seem to me like there's a lot left. You pretty much have the mounting figured out, and that's a huge chunk of the work. After that you'll be able to send your wiring out, order and assemble your axles, mount everything up and plug it in, figure out radiator hoses, and turn the key. Any time you need a hand with this you've got my number! I work for free.

[njccmd2002]

Well technically. But im rebuilding susp. Steering, brakes , its a whole overhaul. Not just a swap.

[njccmd2002]

Well talking with other members and close friends. I wont continue progress thread. I will post end results only and answer questions. No sense in spending time posting, when there is no relly any interest in this swap. I will say i have 6k invested so far. Lol....

Tata...

I will be available for questions via pm.....

[bloodMoney]

Measure EVERYTHING. You know I'm going to have lots of questions when the time comes for me.

[4-eyed-freek]

I got all excited to watch this build and instantly c@*k blocked!

congrats on the great work, cant wait to see this finished up!

[richee3]

[njccmd2002]

I got all excited to watch this build and instantly c@*k blocked!

congrats on the great work, cant wait to see this finished up!

thanks guys, its not that i dont care. its just so sad to talk to yourself. I will post major accomplishments, i just wont go and post, hey i torqued this bolt.

i had to order a new mount, as the one i got (for free, and not complaining) was tweaked from the wreck, cannot fix it, tried. so that sets me back... but its ok...

Measure EVERYTHING. You know I'm going to have lots of questions when the time comes for me.

when you are ready ill loan you my temp mount.. it will make things easier...

[cheela]

but I wanted a bolt by bolt instruction for this.

[Box]

thanks guys, its not that i dont care. its just so sad to talk to yourself.

You trying to tell me something?

This post has been edited by Box: Sep 19, 2014 - 3:53 PM

[perkyshadow]

Bro: As always, you are my hero! I wish I could make it out there to give you a hand! Your ragtop is going to be ridiculously fast! Crazy! Thank you for being awesome enough to post such amazing threads! Seriously! I can't wait to see how this turns out!

[kurt95gt]

Looking good so far

[perkyshadow]

Please... More pictures!

[njccmd2002]

wish i could, competition sent me the wrong tob. Wont go in, so now im stuck. till monday..

[njccmd2002]

engine and tranny ready, newly painted brackets, and cleaned aluminum. Bolts torqued, and loctited..

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thought this was funny!!

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update, 09/20/17... while updating my pictures from photobucket disaster.... i really hate this clutch.....

This post has been edited by njccmd2002: Sep 20, 2017 - 11:06 PM

[Bitter]

Do you have the all metal VVT lines or the metal/rubber VVT lines?

[perkyshadow]

That's what I'm talking about!

[njccmd2002]

Do you have the all metal VVT lines or the metal/rubber VVT lines?

metal lines, its a 2010 engine.... 25k miles. and a major update..

just because i was there... SS clutch line...

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Just kidding, here is the major update.

Credit goes to forgman. need to tweak the bracket... But Im using OEM Mount...

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Need to tweak, need to raise bracket some 3 to 4 mm. to get a good orientation.

This post has been edited by njccmd2002: Sep 20, 2017 - 11:10 PM

[richee3]

That's awesome!

[njccmd2002]

thanks, not going to post pic of the mount, until its fully done. Its a bracket that needs to be made, and BTW all the cuts i did, now i have clearance.... YAY! one step closer...

[Bitter]

Looks like you can almost close the hood on it!

[Smaay]

cant wait till you get it on the road

[Noahwhite2014]

Berto
Once you get running and then get power hungry again afterwards
i will have extra TRD S/C waiting as i now have 2 .. We all know 276 whp is never enough HP!!

HELL YES Supercharge it! (when you're ready ) This v6 swap is going to be so sick and i can only imagine how great its going to feel. Not only just because all that extra engine but because you're doing it with on your own! AWESOME MAN! kudos to you!

[njccmd2002]

cant wait till you get it on the road

very soon

Looks like you can almost close the hood on it!

nope, you cant. but there is nothing fiberglass cant fix.

HELL YES Supercharge it! (when you're ready ) This v6 swap is going to be so sick and i can only imagine how great its going to feel. Not only just because all that extra engine but because you're doing it with on your own! AWESOME MAN! kudos to you!

it wont be a cheap supercharger... and so far, i gave up keeping track of how much ive spent, because its better not to think about it

[njccmd2002]

tack welded only/

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Update 09/20/17 need to start making these for sale....



This post has been edited by njccmd2002: Sep 20, 2017 - 11:16 PM

[Smaay]

what are we looking at here?

[blockustomz]

I love this build.. Thanks for sharing it with us.

[njccmd2002]

It is a bracket and its finalized.

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its not pretty, but does the job, as for measures there are none, it was made trial an error.

this bracket allows the oem mount of the 2GR to mount in the Celica, using the stock GT holes.
this took 7 hours to build.

This post has been edited by njccmd2002: Sep 20, 2017 - 11:20 PM

[enderswift]

The custom stuff is always the hardest. Good work

[Bitter]

Is that going to be strong enough?

[perkyshadow]

Dude... You are my hero, bro!

[njccmd2002]

The custom stuff is always the hardest. Good work

tell me about it.

Is that going to be strong enough?

it actually just supports in the tall spots, the rest is just to mount to chassis. used 1/4 inch steel in the lumps...

Dude... You are my hero, bro!

you want to see more pron!

here is the bracket mount placed.....

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here is the mount attached... note is not complete..

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started a little extension

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fit test...

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after another 3 hours, of thinking and evaluating. here is the final product.... hi res pic....

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here is another pic of the bracket, unpainted...

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so now its official, its fully mounted, now to sort other things....

This post has been edited by njccmd2002: Sep 20, 2017 - 11:37 PM

[Batman722]

Pure awesome.

[kurt95gt]

Nice mount!!

[cheela]

bravo!

[presure2]

very cool berto!! looking forward to more progress!

[njccmd2002]

pickle pickle, exhaust and headers will be a problem. not enough space to route a exhaust pipe... gonna have to get creative...

[Box]

Clearly the solution is header mufflers.

[njccmd2002]

headers arrive today, and will see after that...

and today im proud to mount my pedal...

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bracket finally done, and drying overnight...

This post has been edited by njccmd2002: Sep 20, 2017 - 11:42 PM

[perkyshadow]

What is the pedal for? I may have missed something! And I was thinking you could do throttle bodies through the hood! Hahahaha!

[playr158]

Nice work dude! progress is coming along with great successes!

[njccmd2002]

thanks. 2grfes dont use cable throttles. they are drive by wire and use a specific pedal..

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This post has been edited by njccmd2002: Sep 20, 2017 - 11:46 PM

[playr158]

My cars now and my last car were all drive by wire.
I have to say I miss direct throttle cable soooo much. The only good drive by wire car i've driven extensively is the E46 M3 otherwise.

Are you keeping AC?

[njccmd2002]

Yes. Everything will work. Crossing fingers

[Syaoran]

DBW is bad on stock ECUs. On standalones however it's nearly the same as cable throttle. It responds just as fast, but the direct link feel is lost, because the pedal almost always has less resistance to it.

[njccmd2002]

DBW is bad on stock ECUs. On standalones however it's nearly the same as cable throttle. It responds just as fast, but the direct link feel is lost, because the pedal almost always has less resistance to it.

True. But 275 hp in n/a. With spare parts stateside is appealing to me..

[Bitter]

I'll bet you can take the pedal apart and install a firmer spring

[perkyshadow]

thanks. 2grfes dont use cable throttles. they are drive by wire and use a specific pedal..

You are a crazy man. Crazy genius. But still crazy! I honestly can't even imagine the work just to do the pedal! I'm going to have to come to TN so see this beast when it is finished!

[njccmd2002]

I'll bet you can take the pedal apart and install a firmer spring

I will leave the pedal alone, i dont want it getting stuck.

You are a crazy man. Crazy genius. But still crazy! I honestly can't even imagine the work just to do the pedal! I'm going to have to come to TN so see this beast when it is finished!

the bracket itself took 7 hours, give or take 2. because i had no idea of the positioning of the pedal, so it was trial and error. now that i have a basic idea, should be quicker.

This swap is slow, because im collecting parts as i go. If i break one barrier, i move on to the next. remember, i had no idea the engine would fit in the bay, it would have been a 2700$ loss for me... ( there are cheaper, but not with less than 25K miles and complete with all accessories).

this is the bracket on the car...

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of course had to make sure that

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i used long bolts, and thread locker... Do not want to get loose on me.. Same went for the pedal...

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and next task, will be to find out if these go in with no problem...

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hate to take a loss on them.....

This post has been edited by njccmd2002: Sep 21, 2017 - 12:07 AM

[perkyshadow]

I'll bet you can take the pedal apart and install a firmer spring

I will leave the pedal alone, i dont want it getting stuck.

You are a crazy man. Crazy genius. But still crazy! I honestly can't even imagine the work just to do the pedal! I'm going to have to come to TN so see this beast when it is finished!

the bracket itself took 7 hours, give or take 2. because i had no idea of the positioning of the pedal, so it was trial and error. now that i have a basic idea, should be quicker.

This swap is slow, because im collecting parts as i go. If i break one barrier, i move on to the next. remember, i had no idea the engine would fit in the bay, it would have been a 2700$ loss for me... ( there are cheaper, but not with less than 25K miles and complete with all accessories).

this is the bracket on the car...



of course had to make sure that



i used long bolts, and thread locker... Do not want to get loose on me.. Same went for the pedal...



and next task, will be to find out if these go in with no problem...



hate to take a loss on them.....

Man, I hope they fit! It looks crazy tight already!

[Syaoran]

Good vibes, hope they fit

[Box]

Make them fit!

[bloodMoney]

Are those the Gouky headers?

[njccmd2002]

teaser for tonight, guokys header.....

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im to lazy to post...

This post has been edited by njccmd2002: Sep 21, 2017 - 12:18 AM

[Box]

The real question, how does the rear fit?

[Bitter]

Won't you throw automatic transmission DTC's with the PCM for the 2GR, or did your 2GR come from a manual car?

[Smaay]

yes he will, the only car with a 2GR thats a manual is the Lotus Evora. Most of the AT codes can be defeated except one. The MR2 guys have been fighting it for years.

[Bitter]

And that puts the engine in limp too, doesn't it?

[njccmd2002]

to answer the questions...

1. I know how the rears fit... wont say for now..

2. Yes i will throw a code..

3. it wont put the engine on limp, otherwise i would not have done swap.. (mr2 guys have all of it covered.)

[Bitter]

I remember a fellow with a MZ in their MR2 that was doing funky things with an auto PCM, pulling timing at certain RPM's and I think it was related to the codes thrown.

[Box]

At some point wouldn't it just be easier to use a standalone than to bother with the factory ECU?

[njccmd2002]

At some point wouldn't it just be easier to use a standalone than to bother with the factory ECU?

2 points.

1. yes if you live in an area that does not do obd2 checks.

2. It has not been fully developed yet. So i would rather be safe for now, than sorry, than to blow an engine. I cant tune, and wont be paying hundreds to get it tuned, nor do i have a dyno near.

[Syaoran]

Easier? No. Better? Yes. Cheaper? Hell naw.

For this build the very least you should get is a Sport 1000 from Haltech. That's over $1200 right there.

Make the stocker work for now and you could maybe later on use a standalone as a fuel/ignition controller for tuning purposes. A cheaper one, like a Megasquirt.

[Box]

1. yes if you live in an area that does not do obd2 checks.

Just move further south.

[Bitter]

But you won't pass OBD2 checks with a trans code stored...

[njccmd2002]

well unless you guys chime in (i can pm my paypal), lol, no standalone guys sorry. And as far as the obd codes, working on a solution, possible to get around that transmission codes.

However i dont live in an obd2 check area, so no real worry for the moment.

I wont be spending money on tunes and dynos. period. but thanks for the encouragement.

so far so much money invested on this, that not really looking to invest more than i need to..

This post has been edited by njccmd2002: Oct 26, 2014 - 4:23 PM

[Box]

Just think though, you'll have the only one that we know of. That's exciting.

[njccmd2002]

well im going to post few pics here and there. obstacles to overcome....

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cut to this size to get more clearance

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then see this..

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bend to make this..

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unfortunately that tab, holds the power steering lines and will have to be relocated. But to answer everyones questions, smaller bolt is no longer in the way ...

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it does fit, and i have headers... (740 usd from Gouky)

couple of other things that i have to work... there is no space if you use the regular fans..

no chance for the a/c lines, and will have to use a custom combo...

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cant use the alternator with the stock fans and shrouds. need to get custom or creative..

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relocate the dipstick, move it a little to the side

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clearance with oil cooler. but this one is ok...

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lower radiator hose, will probably have to come from the highlander, or a hybrid mix of both... because the celica hose interferes, so i need to get a hose union or something to mix em together

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upper radiator hose needs to be cut just a tad, careful where u cut it, so that it does not rub with engine..

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relocate the fusebox, you almost most have to it would be in the way of the hose..

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relocate power steering bracket for the reservoir

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then tackle the axle carrier bracket, going to have to weld something or go custom

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as it is, the engine is 1 inch lower than the beams, or 3sge... so long plastic covers...... or maybe they will fit, only future will tell....

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so if this is not a clear description of what needs to be done to the car, i dont know what is...

This post has been edited by njccmd2002: Sep 21, 2017 - 12:51 AM

[mkernz22]

Is the PS axle going to fit with the header there? It might be the angle of the picture, but it looks like a pretty close call.. Props on all the work though, absolutely amazing.

This post has been edited by mkernz22: Oct 27, 2014 - 9:54 AM

[njccmd2002]

it fits, it is proven by guoky... that was never an issue. but i know the pic looks bad...

[Box]

You must have the patience of a saint, I'd have set everything on fire by now.

[Syaoran]

My recommendation is to take out that double core radiator, keep the stock fans and a stock radiator. A good quality replacement.

Since you're going N/A you won't need a huge radiator at all, especially since you're probably using a GT-4 hood to clear the engine, right? The stock radiator is good enough for a 3S-GTE GT-4, should be good enough for a 2GR N/A. I'm actually considering removing mine and replacing it with a stock one, since I never really saw any huge improvements on cooling, my temperature problems turned out to be tuning related.

[njccmd2002]

well some guys are running bigger radiators, since the engine requires higher pressure radiator cap. I had a stock radiator, and traded for this aluminum, in the future i may need it if i decide to supercharge.. however, i already have a solution planned....

[njccmd2002]

just as suspected.

ps lines nightmare, A/c nightmare. I have to reroute these lines, as the mount is in the way.. and the a/c lines are to close to engine..

[Box]

Who needs A/C in a convertible anyway? What real man needs power steering? See, just solved your problems.

[perkyshadow]

Can you do stainless flex hoses? I don't know, I'm just asking! I replaced the clutch hose in my Z with a stainless flexible deal. Well... I ADDED the clutch line since it didn't actually have one to begin with!

[Bitter]

Electric power steering man...steal the system from a MR-2! You can mount the pump wherever and plumb the lines as needed.

[njccmd2002]

i tought about it, even found several sites, and swaps for it. cost is about the same, but i have the pump, the belt, the pulleys, and notched the frame.

so the easiest way is to route the lines different ways, easy peasy. Working this week, so no updates for now.

just more work but i got it sorted out...

[njccmd2002]

i have done several things but this takes the cake...

today i learned the wrong way, that i got a harness from the lexus es350. turns out the engine harness is not same as the engine room harness.

Purchased the harness in june, and I TOUGHT IT HAS both ecu clips to use for the rav 4, however, silly me, no engine harness.

turns out they are 2 different things. somehow the engine harness connects at the fuse box. lol.....

at a great cost.... 170 $$$ YIKES

when i saw headlights attached and yellow split looming with sensors, i said oh, oh...

well this harness has the small ecu plug 90980-12461 with wires, and a pedal connector 90980-12303 attached to it.

guess they are separated harness... I need both housings...

well i found today in a japanese site 90980-12396 is the number for the big housing.... Im eeying plugs on ebay, and made offer, if all else fails..

This really sets me back a whole deal... i was ready to start wiring....

And funny thing, this harness has like 3 more plugs that can be used for the pedals.

Probably sell them with pigtails and recoup money that way...

it has the fuse box, and smog sensor and airbag sensor :mad2:mad2

none of which i need.

[njccmd2002]

ok so to give an update. and for the records.

im going to have to make a hybrid harness from the original highlander, which has 5 plug ecu, with the harness of the 2 plug ecu. I have the smaller plug, and may have to order the bigger plug..

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es350 harness, not engine, (has only one plug)

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need this...

90980-12396



also spent several days. with this.. (been done by a few at the mr2oc swaps....

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did not take pics of the new parts, but there were a few to mount the belt, some bearings, and bolts..

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modified brackets for the power steering rack...

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made a mock of the rack...

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since lines are going behind, need a custom line for the high pressure side...

removed the vacuum lined, and hacked it in pieces to use for the low pressure ps line

also mocked the low pressure ps line..

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used a torch to bend

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it has some leaks, but its ok. it will be fixed...

This post has been edited by njccmd2002: Sep 21, 2017 - 1:37 AM

[Bitter]

Fill the tubing with sand then cap the ends and then bend, or you can freeze water inside and then bend it before it melts.

[njccmd2002]

nice tips, but i already bent it, wish i knew. the leaks are because it has been welded too.